HANOI UNIVERSITY OF SCIENCE AND TECHNOLOGY

SCHOOL OF MECHANICAL ENGINEERING

MECHATRONICS SYSTEM DESIGN

PRODUCT SORTING SYSTEM

Student’s Name: Nguyen Duy Tung Anh

Student’s ID: 20195759
Instructor: PhD. Hoang Hong Hai
Class code: 734461

June 2023
 TABLE OF CONTENTS

TABLE OF CONTENTS .............................................................................................. i

PREFACE ....................................................................................................................iii

LIST OF FIGURES ...................................................................................................... v

LIST OF TABLES .....................................................................................................viii

CHAPTER 1. INTRODUCTION OF THE MECHANICAL SYSTEM ................. 9

1.1 System Overview .................................................................................................. 9

1.1.1 Definition and Application ............................................................................. 9

1.1.2 Principle of Product Sorting Systems ........................................................... 16

1.1.3 Basic Elements in A Typical Product Sorting System ................................. 17

1.2 System in Detailed .............................................................................................. 19

1.2.1 System Transmission Schematic .................................................................. 19

1.2.2 Conveyor Belt ............................................................................................... 19

1.2.3 Motor Selection............................................................................................. 24

1.2.4 Chain Drive ................................................................................................... 26

1.2.5 Shaft and Bearing.......................................................................................... 26

1.2.6 Pneumatic Cylinder....................................................................................... 27

1.2.7 Sensors .......................................................................................................... 29

1.2.8 Programmable Logic Controller ................................................................... 33

1.2.9 Relay ............................................................................................................. 34

1.3 System 3D Model ................................................................................................ 35

1.3.1 Conveyor Frame ........................................................................................... 35

1.3.2 Conveyor Belt ............................................................................................... 35

1.3.3 Motor ............................................................................................................ 36

i|Page
 1.3.4 Chain Drive ................................................................................................... 37

1.3.5 3D Model of the Product Sorting System ..................................................... 38

1.4 System Control Charts ........................................................................................ 39

CHAPTER 2. CONTROL SYSTEM CONFIGURATION .................................... 41

2.1 Control Principle ................................................................................................. 41

2.1.1 Operational Block Diagrams ........................................................................ 41

2.1.2 MANUAL Mode’s Principle ........................................................................ 42

2.1.3 AUTO Mode’s Principle ............................................................................... 44

2.2 Electric Components Selection ........................................................................... 45

2.2.1 LED Indicator Lights .................................................................................... 45

2.2.2 Push Buttons ................................................................................................. 46

2.2.3 Emergency Stop Buttons .............................................................................. 47

2.2.4 Rotary Switch for MANUAL/AUTO Running Mode .................................. 47

2.2.5 Proximity Sensors ......................................................................................... 48

2.2.6 General Purpose Relays ................................................................................ 49

CHAPTER 3. CONTROL PROGRAM AND DIAGRAMS .................................. 52

3.1 Control Program Specifications .......................................................................... 52

3.1.1 Inputs and Outputs ........................................................................................ 52

3.1.2 PLC Program Blocks .................................................................................... 53

3.1.3 The Simulation Program Interface in TIA Portal V16 ................................. 64

3.2 Control System Diagrams ................................................................................... 65

3.2.1 The Component Connection Diagram .......................................................... 65

CHAPTER 4. CONCLUSION .................................................................................. 66

ACKNOWLEDGEMENT ......................................................................................... 66

REFERENCES .............................................................................................................. .

ii | P a g e
 PREFACE

Automation is a technique that uses technical or mechanical instruments to

complete a process or operation with minimum human intervention. Nowadays many
associate the term ‘automation’ with advanced technologies such as artificial
intelligence (AI), machine learning, and robotics. It is the process of making a process
or system run automatically. Automation affects practically every business, including
installation, maintenance, production, marketing, sales, medical, design, procurement,
and management. Automation has transformed the fields into which it has been
introduced, and there is hardly a facet of modern life that has not been influenced by it.
Automation technology has progressed to the point that it has spawned many new
technologies.
Automation is not a new concept; it stretches back millennia to when humans built
simple automating equipment such as pulleys to make labor easier. It is the use of
various control systems to operate equipment such as machinery, factory operations,
vehicle steering, airplanes, ships, and other applications. Due to the ongoing
advancement of technology, a quick and simple application in modern business is
required. It is a feasible method for increasing speed and accuracy while decreasing
labor costs. It can be achieved by several different means including mechanical,
electrical, electronic devices and computers, and hydraulic systems. Industries that
involve very complicated systems such as modern factories, aircraft, and ships often use
a combination of different automation techniques in order to maximize their process
efficiencies.
The automated control of production and product processing has expanded in
Vietnam throughout the age of industrialization and modernization. As a consequence,
adaptable production systems based on CNC machines and industrial robots are formed,
providing a high degree of automation for small and medium-batch manufacturing. The
product categorization system, which is a key stage in determining the quality of
commercial items, is also automated.

iii | P a g e
 The project "Mechatronics System Design" was carried out to reinforce students'
understanding while also assisting them in recognizing the relationship between
theoretical knowledge and actual applications and use. The topic has several essential
applications in sectors such as product transportation, counting, and categorization.
Labor and manufacturing expenses can be minimized with this automation technology.

iv | P a g e
 LIST OF FIGURES

Figure 1.1 Color Sorter Schematic [1] ......................................................................... 10

Figure 1.2 Sorting System Based on Item’s Height [2] ............................................... 10
Figure 1.3 Sorter by Weight with Tilt Tray Mechanisms [3] ....................................... 11
Figure 1.4 Barcode Sorter [4] ....................................................................................... 12
Figure 1.5 Pop-up Wheel/Roller/Belt Sorter [5] .......................................................... 13
Figure 1.6 Pivoting Arm Sorter [6] .............................................................................. 13
Figure 1.7 Pusher Sorter [7] ......................................................................................... 14
Figure 1.8 Tilt Tray Sorter [8] ...................................................................................... 14
Figure 1.9 Cross Belt Sorter [9] ................................................................................... 15
Figure 1.10 Push Tray Sorter [10] ................................................................................ 15
Figure 1.11 Bombay Sorter [11] ................................................................................... 16
Figure 1.12 Basic Block Diagram of Object Product Sorting System ......................... 16
Figure 1.13 A Typical Single Conveyor [12] ............................................................... 17
Figure 1.14 Typical Single Belt/Chain Drive [13] ....................................................... 17
Figure 1.15 A Typical Pneumatic Cylinder [14] .......................................................... 18
Figure 1.16 Photoelectric Sensor Schematic [15] ........................................................ 18
Figure 1.17 Typical Motor Model ................................................................................ 19
Figure 1.18 System Transmission ................................................................................ 19
Figure 1.19 Typical Conveyor Belts [16] ..................................................................... 21
Figure 1.20 Typical Roller Conveyor [17] ................................................................... 22
Figure 1.21 Typical Roller Conveyor [18] ................................................................... 22
Figure 1.22 Typical Chain Conveyor [19] ................................................................... 23
Figure 1.23 Typical Slat Conveyor [20] ....................................................................... 23
Figure 1.24 Double Acting Cylinder Principle [21] ..................................................... 28
Figure 1.25 5/2-way Valve [22] ................................................................................... 28
Figure 1.26 5/2-way Valve in Double Acting Pneumatic Cylinder Controlling .......... 29
Figure 1.27 Some Popular Sensor on the Market ......................................................... 30
Figure 1.28 OMRON E3F3 .......................................................................................... 32
Figure 1.29 OMRON E3F3 Datasheet ......................................................................... 32
v|Page
Figure 1.30 Programmable Logic Controller (PLC) .................................................... 33
Figure 1.31 Relay ......................................................................................................... 34
Figure 1.32 The Conveyor Frame 3D Model ............................................................... 35
Figure 1.33 The PVC Belt 3D Model ........................................................................... 36
Figure 1.34 The Motor with Built-in Gear-drive 3D Model ........................................ 36
Figure 1.35 The Large Sprocket 3D Model.................................................................. 37
Figure 1.36 The Small Sprocket 3D Model.................................................................. 37
Figure 1.37 The Final 3D Model of the Product Sorting System................................. 39
Figure 1.38 The General Control Chart ........................................................................ 39
Figure 1.39 The General Control Chart ........................................................................ 40
Figure 1.40 The Automatic Mode Control Chart ......................................................... 45
Figure 2.1 General Block Diagram .............................................................................. 41
Figure 2.2 The Simplified System’s Layout................................................................. 42
Figure 2.3 The Simplified System’s Layout................................................................. 43
Figure 2.4 The AUTO Mode Block Diagram ............................................................. 45.
Figure 2.5 AD16-22DS LED Indicator Lights [26] ..................................................... 46
Figure 2.6 LA38 Spring Return Push Buttons [27] ...................................................... 46
Figure 2.7 LA38-11ZD Spring Back with Self-locking Push Button [28] .................. 47
Figure 2.8 LA38-11 Rotary Switch for MANUAL and AUTO Mode [29] ................. 48
Figure 2.9 OMRON E3F3 Photoelectric Sensor [30] .................................................. 48
Figure 2.10 The Specification of OMRON E3F3 Photoelectric Sensor [30]............... 49
Figure 2.11 OMRON MY2N 24VDC General Purpose Relay [31] ............................ 50
Figure 3.1 PLC Main Input Tags .................................................................................. 52
Figure 3.2 PLC Output Tags ........................................................................................ 53
Figure 3.3 PLC Intermediate (Middle) Tags ................................................................ 53
Figure 3.4 PLC Program Blocks .................................................................................. 53
Figure 3.5 Network of Main Program Blocks .............................................................. 55
Figure 3.6 Network of the Output Functional Block .................................................... 56
Figure 3.7 Network of the Manual Operation Functional Block ................................. 57
Figure 3.8 Reset Network of the Automatic Operation Functional Block ................... 58
Figure 3.9 Operating Networks of the Automatic Functional Block ........................... 61
vi | P a g e
Figure 3.10 Network for Simulating the Sorting Process as the Movement of the
Product on the Conveyor .............................................................................................. 62
Figure 3.11 Network for Simulating the Sensor Activations ....................................... 64
Figure 3.12 Simulation Interface in TIA Portal V16 Using SIMATIC Module .......... 64
Figure 3.13 Using the TIA Portal V16 Inteface to Simulate Manual Operation ........ 64.
Figure 3.14 Using the TIA Portal V16 Inteface to Simulate Automatic Operation .... 65.
Figure 3.15 PLC Connection Diagram. ........................................................................ 65

vii | P a g e
 LIST OF TABLES

Table 1.1 Project’s Calculating and Designing Inputs ................................................. 24

Table 1.2 Chain Drive Parameters ................................................................................ 26
Table 1.3 Shaft Parameters ........................................................................................... 26
Table 1.4 The Specification of OMRON E3F3 Photoelectric Sensor .................51

viii | P a g e
 CHAPTER 1. INTRODUCTION OF THE MECHANICAL
SYSTEM

1.1 System Overview

1.1.1 Definition and Application
In the last few decades, as the status of instability in China’s industrial policies
and the need of decreasing reliance on a single country, global manufacturing
companies started to shift their supply chains to other countries within the area. Vietnam
is one of the best choices. Vietnam has one of the world’s most important strategic and
valuable geographical locations, which is a significant link in the global logistics
network. Vietnam also “catches the eye” with its international airports/seaports and
transportation effectiveness, compared to other ASEAN countries.
Therefore, the local suppliers and manufacturing facilities undoubtedly require
automation and renovation for their systems. These changes usually begin in frequently
repeated procedures, such as feeding, distributing, measuring, packing, handling,
separating, classifying, and sorting. This Project’s Report focuses on the sorting
procedure or the Product Sorting System.
Usually, sorting can be seen as two different procedures merging into one. On a
typical manufacturing line, when an item comes to a station it will be sorted based on
its aspects (colors, parameters, weight, etc.) and then separated into the desired
following production lines by different methods/mechanisms (tilt trays, pushers,
sweepers, etc.).
There are multiple product sorting systems based on their applications in the
industrial sector or the industrial field. By the aspects of the items, product sorting
systems can be divided into four main categories:
● Sorting by colors: Color sorters (color sorters) separate items by their colors. They
detect the color of objects passing in front of them and sort them into desired
groups by different mechanisms.

9|Page
 Figure 1.1 Color Sorter Schematic [1]
1) Sensor; 2) Light source; 3) Separating mechanism
A color sorter includes 3 main parts (Figure 1.1). The types of sensors and light
sources based on the applying technologies could be traditional photoelectric
sensors; CCD cameras with LED light sources; infrared light sources with
microwave detectors; or even X-ray systems. The separating mechanisms can be
mechanical or pneumatic devices.
● Sorting by dimensional parameters: Dimension sorters can be seen as height
sorters, width sorters, some other dimensional aspects, or even a combination of
dimensional aspects. Usually, this type of system has its range of items and the
sensors are set up to specifically sort those items by their dimensions. The sensors
can be infrared, CCD cameras, or as simple as limit switches.

Figure 1.2 Sorting System Based on Item’s Height [2]

10 | P a g e
 The applications of this type of system can be regularly seen in the beverage
industry (Figure 1.2). Another typical use of dimensional parameter sorters is in
warehouse management. The boxes of items can be sorted and diverted into
specific places to optimize the storage spaces.
● Sorting by weight: The weight sorters can divert items with various weight
spectrums to desired production lines more precisely than manual operation. For
example, seafood is extremely valuable, so the more accurate the measurements
are the more money and time it can save for the business.

Figure 1.3 Sorter by Weight with Tilt Tray Mechanisms [3]

In Figure 1.3, the sorter has tilt tray mechanisms with a built-in load sensor in each
tray. Moreover, the sensors in some simple cases are just simple mechanisms like
adjustable load springs.
● Sorting by barcode: With the same separating mechanisms and principles (tilt tray,
cross belt, pusher, sweeper, etc.), barcode sorters only have different sensors—
barcode readers (Figure 1.4) instead of other technologies.

11 | P a g e
 1

Figure 1.4 Barcode Sorter [4]

1) Barcode reader; 2) Barcode on the items
In some cases, barcodes can be replaced by QR codes or similar technologies.
The mechanisms of automated product sorting systems are generally in one of
these two groups: Unit sorters (individual items). and case sorters (the whole cases,
totes, or orders of products). In some special cases, sorters can operate both for units
and cases.
Cases sorters consist of:
● Pop-up wheel/roller/belt (strip belt) sorter: the wheels, rollers, or belts “pop up”
to lift or move items at a 30° or 90° angle to the next production line (Figure 1.5)
— 40-100 cartons per minute;

12 | P a g e
 Figure 1.5 Pop-up Wheel/Roller/Belt Sorter [5]
● Pivoting arm sorter: when the arm is actuated, it pivots into position, redirecting
and sorting a case onto a secondary takeout line (Figure 1.6) — 50-100 cases per
minute;

Figure 1.6 Pivoting Arm Sorter [6]

● Pusher Sorter: made up of one or more pneumatically actuated pushers attached
to a belt conveyor belt. When activated, the pusher extends at a right angle to the
production line, successfully diverting a case or tote into a secondary belt or slider
for additional processing (Figure 1.7) — 10-30 cartons per minute.

13 | P a g e
 Figure 1.7 Pusher Sorter [7]
Unit sorters consist of:
● Tilt tray sorter: consists of trays mounted to a series of carts linked together into a
train of trays, which carry product and run in a continuous loop (Figure 1.8) —
100-200+ cartons per minute;

Figure 1.8 Tilt Tray Sorter [8]

● Crossbelt sorter: consists of a tiny conveyor belt running perpendicular to the
loop’s decks. When the belt is triggered, the product is transferred or pushed off
the loop conveyor belt and into the next lines (Figure 1.9) — 100-200+ cartons
per minute.

14 | P a g e
 Figure 1.9 Cross Belt Sorter
● Push tray sorter: has the basis as the tilt tray sorter, but uses a push bar to divert
items instead of gravity (Figure 1.10) — 30-60 cartons per minute.

Figure 1.10 Push Tray Sorter

● Bombay sorter: consists of trays that open to dump product and function as real
trap doors (the concept gets its name from the bomb bay featured in military
airplanes). The items can be dumped into a gravity funnel for manual sortation, or
they can be dropped straight into a shipment carton or tote (Figure 1.11) — 100-
230 trays per minute.

15 | P a g e
 Figure 1.11 Bombay Sorter

1.1.2 Principle of Product Sorting Systems

A product sorting system is as simple as its name, whose main purpose is to sort
the desired items in specific ways based on the item’s aspects. The basic function blocks
of a product sorting system include the sensors, the processor, the controller, the power
supply, the actuators, and the main sorting mechanisms (as shown in Figure 1.12).

Figure 1.12 Basic Block Diagram of Object Product Sorting System

As mentioned above, a typical classification process starts when an item comes to
the station, then based on its characteristics and the sorting requirements, it will be
sorted into specific groups by different methods and mechanisms.
Each function block in a product sorting system has its own technical standards
and criteria that need to be met. Respectively, we have:
• Sensing, processing and controlling block: Need to have high accuracy and
working reliability;

16 | P a g e
 • Working block (the actuators and sorting mechanisms): Need to have a high
response speed, and at least can keep up with the other function blocks.
• Power supply block: Need to have high efficiency, working reliability, and
stability.

1.1.3 Basic Elements in A Typical Product Sorting System

Specific mechanism in each system of sorting acquires different parts and
components to work. Nonetheless, there is a typical pattern of elements that most
systems follow. A basic product sorting system often includes:
• Conveyor: Different projects require different types of conveyors. In this project,
belt conveyor is utilized, specifically the single conveyor belt (Figure 1.13).

Figure 1.13 A Typical Single Conveyor

• Chain Drive, or Belt Drive, depending on the circumstances (Figure 1.14).

Figure 1.14 Typical Single Belt/Chain Drive

• Pneumatic Cylinder (Figure 1.15)

17 | P a g e
 Figure 1.15 A Typical Pneumatic Cylinder
• Sensors: based on the requirements of the system, the manufacturer chooses one
kind of sensor that suits the function of that classification mechanism. The system
designed and proposed in this project uses a photoelectric sensor (Figure 1.16).

Figure 1.16 Photoelectric Sensor Schematic

• Motors: It is a necessity to have a motor on any electrical-supplied system. Motor
plays a vital role in the system and needs to be powerful enough to supply the
whole mechanism. Depending on the requirements and specification of the
system itself, the capacity balance of the factory, and other factors that affect the
design, such as weight, compatibility, price, power, etc., the motor of any system,
and sorting system, specifically, must be chosen carefully to fit in.

18 | P a g e
 Figure 1.17 Typical Motor Model

1.2 System in Detailed

1.2.1 System Transmission Schematic

Figure 1.18 System Transmission

1.2.2 Conveyor Belt

A belt conveyor system's carrying medium is a conveyor belt (often shortened to
conveyor). One sort of conveyor system is a belt conveyor system. A belt conveyor
19 | P a g e
system is made up of two or more pulleys (also known as drums) and a closed loop of
carrying medium—the conveyor belt—those spins around them. The belt and the
material on the belt are moved forward by one or both of the pulleys. The powered
pulley is referred to as the drive pulley, whereas the unpowered pulley is referred to as
the idler pulley.
Conveyors are long-lasting and reliable components that are employed in
automated distribution and storage, as well as manufacturing and production facilities.
This, in conjunction with computer-controlled pallet handling technology, enables more
effective retail, wholesale, and factory distribution. It is a labor-saving method that
allows huge quantities to flow quickly through a process, letting businesses send or
receive higher volumes with less storage space and personnel price.
Because they are the most adaptable and least priced, belt conveyors are the most
often utilized motorized conveyors. Products are delivered directly on the belt, allowing
for the movement of both regular and irregularly shaped things, large or tiny, light or
heavy.
The requirements for the conveyor belt are:
• Space: A conveyor system requires a lot of areas to function effectively. This stage
entails finding any contact points, clearances, impediments, or other regions that
might restrict material passage;
• Load capacity: Before constructing the piece, the weight of transportation must be
supplied. Overloading a system might lead it to break down or halt in the middle
of its activity. The overall length, bed breadth, and driving mechanism all have an
impact on load capacity;
• Speed: A conveying system's speed is measured in meters per second (m/s). Most
conveying systems have an average speed of 0.3302 m/s, which is how fast a
human moves when carrying a 20 kilogram item. Though this is average, the speed
may be adjusted to suit the application;
• Configuration: Conveying systems are available in a range of shapes, designs,
sizes, and configurations. They might be straight, inclined, horizontal, or curved,
and they can incorporate pockets or slats as well as z-frames. Each system is
tailored to a specific need;
20 | P a g e
 • Driving system: The driving system, or drive, is the power that moves materials
in an automated conveying system. It has a counter bearing to keep items moving
and to make travel along the belt easier. They can be built to convey items in either
direction and positioned at the system's center, end, or origin. Depending on their
design, drive systems can have a single or variable speed. They generally feature
a gear system that is powered by a motor. Variable speed drives have become
common for contemporary conveying because they allow for material flow
variations;
• Safety: Conveyor systems are governed by the Occupational Safety and Health
Administration (OSHA) and must fulfill federal safety standards. All conveyor
manufacturers are aware of the requirements and follow them. Conveying systems
are a preventative measure that keeps personnel from having to lift and carry heavy
goods.
Conveyor belts are the most common and fundamental form of conveyor, with
transmission rates ranging from slow to fast. They feature a moving belt supported by
a steel frame, which likewise supports the belt and the cargo being conveyed. Sliding
doors are ones that have a supporting framework beneath them. The belt is supported
by closely spaced rollers in a roller belt arrangement (Figure 1.19). Belt conveyors are
available in several sizes, lengths, and lanes.

Figure 1.19 Typical Conveyor Belts

Gravity roller conveyors are made up of a series of rollers that are evenly spaced
and coupled to a side frame (as shown in Figure 1.20). The rollers' location gives a
surface on which to lay things for movement. Materials are moved by gravity when a

21 | P a g e
roller conveyor is slanted or installed at an angle. Shipping businesses employ gravity
roller conveyors to load and unload vehicles.

Figure 1.20 Typical Roller Conveyor

Motorized roller conveyors utilize motors installed along the conveyor frame to
power rollers that are regularly spaced (as shown in Figure 1.21). With the inclusion of
motors, the architecture is similar to that of a gravity conveyor. The number of motors
required is determined by the load to be transported as well as the overall architecture
of the system. A chain or belt might be used to link the rollers. In certain systems, a
sensor begins and stops the motor to prevent parts from becoming entangled.

Figure 1.21 Typical Roller Conveyor]

Chain conveyors feature two or more sets of chains that make contact with the
bottom of the goods to be conveyed (Figure 1.22). While being transported, the
materials rest on the chains. Chain operated conveyors are good for objects with uneven
bottom surfaces or that are particularly heavy. Pallets can be put directly on heavy-

22 | P a g e
framed ones. Chain conveyors move quite slowly because of the sorts of goods they
transport.

Figure 1.22 Typical Chain Conveyor

Slat conveyors are similar to chain conveyors in that flat slats are attached to the
chain. They are comparable to belt conveyors in several aspects, except that slats replace
the belt (as shown in Figure 1.23). The smooth surface of the slats minimizes damage
or injury to the goods being moved, making them excellent for assembly applications.
Slat conveyors can be loaded and unloaded utilizing robotic automation since the
surface is smooth and free of impediments.

Figure 1.23 Typical Slat Conveyor

Based on the requirements of the project, the shape and size of the products in
process of sorting, the efficiency of the system and, consider the compatibility, size, and
power of motor…, this project uses belt conveyor mechanism as the mechanism of
23 | P a g e
transmitting. As the total load is lightweight, with simple structure and considerably
small size, moving in a straight line during the transmission, belt conveyor is the most
suitable mechanism to install for the project.
Table 1.1 Project’s Calculating and Designing Inputs
Productivity Item’s weight range Item’s geometrical parameters (cm)
N Qmin Qmax Cylindrical shape Cubic shape
(items/min) (kG) (kG) h1;d1 h2;d2 h3;d3 h1 h2 h3
15 0.3 5.5 5;5 7;5 3;5 5 7 10

From the requirement of Design Project 1 as in Table 1.1, the following conveyor
belt parameters:
• The maximum loading on the conveyor belt: ΣQmax = 27.5 kG;
• The width of conveyor belt: W = 150 mm;
• The thickness of conveyor belt: H = 3 mm;
• The working length of conveyor belt: Lw = 1350 mm;
• The standard chosen length: L = 1500 mm;
• The velocity of conveyor belt: v = 0.075 m/s;
• The standard roller diameter: d = 60 mm.

1.2.3 Motor Selection

An electric motor is a device that transforms electrical energy into mechanical
energy. Most electric motors create force in the form of torque imparted to the motor's
shaft by interacting between the magnetic field of the motor and electric current in a
wire winding. Mechanically, an electric generator is identical to an electric motor, but
it runs with a reversed flow of power, transforming mechanical energy into electrical
energy.
Direct current (DC) sources, such as batteries or rectifiers, or alternating current
(AC) sources, such as a power grid, inverters, or electrical generators, can power electric
motors.
Electric motors are classed based on factors such as power source type,
construction, application, and motion output type. They can be powered by alternating

24 | P a g e
current or direct current, brushed or brushless, single-phase, two-phase, or three-phase,
axial or radial flux, and air- or liquid-cooled.
Common types of electric motors are:
• AC brushless motor: AC brushless motors are widely used in motion control. They
utilize synchronous rotation of the stator and rotor by induction of a rotating
magnetic field created in the stator. They are powered by permanent
electromagnets.
• DC brushless motors were initially intended to offer superior performance in a
smaller area than DC brushed motors, and they are smaller than equivalent AC
counterparts. In the absence of a slip ring or commutator, an integrated controller
is utilized to assist with operation.
• Stepper motors: employ an internal rotor that is electrically modulated by external
magnets. Permanent magnets or soft metals might be used to make the rotor. The
rotor teeth align with the magnetic field as the windings are activated. This enables
them to move from one location to another in set increments.
• Servo motors: A servo motor is any motor that is linked with a feedback sensor to
aid in positioning; consequently, servo motors are the foundation of robotics.
There are both rotary and linear actuators employed. Brushed DC motors are
widespread, but brushless AC motors are taking their place in high-performance
applications.
In this project, the chosen motor is a DC motor (brushless) with the following
characteristics: it is affordable and suitable for the scale of this project. Moreover, the
DC motor is considered a simple element, straightforward to operate, lightweight, and
sustainable. It is also easy to replace such a simple and cheap element.
With the calculation guidelines, the required power on the motor’s shaft Pct and the
preliminary speed on the motor’s shaft nsb, as follows: Pct = 24.6 (W) and nsb = 477.4
(rpm), then, we can select the motor using Wanshin’s catalog. Choosing the motor
number 80YS25DV22 which has:
• The output power is Pdc = 25 (W);
• The output speed is ndc = 500 (rpm);
• Input voltage: 220 (V).
25 | P a g e
 1.2.4 Chain Drive
In general, chain and belt drives are most commonly used to transmit power from
one point to another. Considering all the pros and cons of the two mechanisms, the chain
belt is certainly more suitable for the project.
From all the calculations and selections, the chain drive parameters can be
summarized in the following table:
Table 1.2 Chain Drive Parameters
Specification Symbol
Chain type Bush roller chain
Chain pitch t 12.7 (mm)
Number of links x 100
Shaft distance a 388.9905 (mm)
Small sprocket’s teeth number z1 25
Large sprocket’s teeth number z2 51
Sprocket’s material Gray cast iron
Small sprocket’s pitch diameter d1 101.33 (mm)
Large sprocket’s pitch diameter d2 206.30 (mm)
Small sprocket’s outside diameter da1 106.881 (mm)
Large sprocket’s outside diameter da2 212.259 (mm)
Bottom radius r 3.94 (mm)
Small sprocket’s bottom diameter df1 93.45 (mm)
Large sprocket’s bottom diameter df2 198.42 (mm)
Force acting on the shaft Frx 266.67 (N)

1.2.5 Shaft and Bearing

From all the calculations and selections, the shaft and bearing parameters can be
summarized in the following table.
Table 1.3 Shaft Parameters
Specifications

26 | P a g e
 The sprocket mounting diameter 15 (mm)
The bearing mounting diameter 20 (mm)
The conveyor belt mounting diameter 60 (mm)
The bearing number 1000904
Keyed joint Interference fit
The key width 5 (mm)
The key height 5 (mm)
The keyhole depth on the shaft 3 (mm)
The keyhole depth on the sleeve 2 (mm)
The key length 28 (mm)

1.2.6 Pneumatic Cylinder

Pneumatic cylinders are classified into three types:
• Cylinders with a Single-Acting Mechanism (Single-Acting Cylinders);
• Cylinders with Dual Action (Double-Acting Cylinders);
• Cylinders that can be extended (Telescoping Cylinders)
Double-acting pneumatic cylinders work on both ends of the piston, with one
element utilized for outstroke and the other for in stroke. While single-acting pistons
are more usually seen in internal engines, double acting pistons can be found in
machinery such as steam engines, which is known as exterior engines. This is because
double acting pneumatic cylinders (as shown in Figure 1.24) generate force from both
ends of the piston. It is the most suitable pneumatic cylinder for the project. Thanks to
the ability of removing all substances out of the chamber, making it completely empty,
the double acting cylinder can provide a long travel distance with a relatively constant
force during each cycle. When running at greater speeds, this cylinder gives pretty
excellent control of the apparatus. The system requires motion in straight line, so a
Double-acting cylinder with straight movement is chosen.

27 | P a g e
 Figure 1.24 Double Acting Cylinder Principle
A 3/2 pneumatic valve is paired with the cylinder to control its motion of it
properly.

Figure 1.25 3/2-way Valve – 24V DC

A 3/2 valve has three ports and two positions. The two positions refer to two different
working positions (ON, OFF) of the pneumatic solenoid valve core. The valve core
controls different gas passages when the valve gains and losses power.
The pneumatic valve body has three ports, i.e. A, P and T, of which one (P) is for inlet
and two (A & T) are for outlet: one of the outlets is normally open and the other is
normally closed. A 3/2 valve is usually used together with a single acting pneumatic
actuator and adopts a single electric control, namely the single coil.

28 | P a g e
 Figure 1.26 3/2-way Valve in Double Acting Pneumatic Cylinder Controlling
The standard value D = 16 (mm) (Figure 3.26) with the standard stroke of S = 200
(mm) is chosen, specifically, the CDJ2B16-200Z model. The air compressor is
commonly chosen as the Btec BT2024 with a tank volume of around 24 liters.

1.2.7 Sensors
A sensor, in the widest sense, is a device, module, machine, or subsystem that
detects events or changes in its surroundings and transmits the data to other electronics,
most often a computer processor. Sensors are a type of equipment that is widely utilized
nowadays, particularly in the fields of industry and communication. A sensor recognizes
physical or chemical components where it is situated and then converts it into encoded
information that may be transferred to a monitor, computer, or PLC system to operate
other devices remotely. Information is processed to extract qualitative or quantitative
parameters of the environment, serving the needs of scientific, technical or people's
research, and briefly called measurement, serving in information transmission and
processing, or in controlling other processes.
Sensors are classified in many ways. Some are simple, while others are extremely
intricate.
The sensors are separated into two categories in the first classification: active and
passive. Active sensors require an external excitation or power signal to function.
Passive sensors, on the other hand, do not require any external power supply and
create output responses directly.

29 | P a g e
 The other type of classification is based on the method of detection used in the
sensor. Detection methods include electric, biological, chemical, and radioactive
detection.
The following classification is based on conversion phenomena, namely the input
and output. Photoelectric, thermoelectric, electrochemical, electromagnetic, thermotic,
and other frequent conversion phenomena are listed here.
Analog and digital sensors are the last classifications of sensors. Analog Sensors
generate an analog output, which is a continuous output signal (typically voltage, but
other quantities such as resistance, etc.) In relation to the quantity being measured.
In contrast to analog sensors, digital sensors function with discrete or digital data.
The data in digital sensors is digital in nature and is used for conversion and
transmission.

Figure 1.27 Some Popular Sensor on the Market

A typical sensor has the following characteristics:
Accuracy of a sensor indicates how much the sensor signal correctly represents
the measured quantity after it stabilizes (i.e. beyond the transient period.) Important
static characteristics of sensors include sensitivity, resolution, linearity, zero drift and
full-scale drift, range, repeatability, and reproducibility.

30 | P a g e
 Sensitivity is a measure of the change in output of the sensor relative to a unit
change in the input (the measured quantity.)
Resolution is the smallest amount of change in the input that can be detected and
accurately indicated by the sensor.
Linearity is determined by the calibration curve. The static calibration curve plots
the output amplitude versus the input amplitude under static conditions. Its degree of
resemblance to a straight line describes the linearity.
Drift is the deviation from a specific reading of the sensor when the sensor is kept
at that value for a prolonged period of time. The zero drift refers to the change in sensor
output if the input is kept steady at a level that (initially) yields a zero reading. Similarly,
the full -scale drift is the drift if the input is maintained at a value which originally yields
a full-scale deflection. Reasons for drift may be extraneous, such as changes in ambient
pressure, humidity, temperature etc., or due to changes in the constituents of the sensor
itself, such as aging, wear etc.
The range of a sensor is determined by the allowed lower and upper limits of its
input or output. Usually, the range is determined by the accuracy required. Sometimes
the range may just be determined by physical limitations.
Repeatability is defined as the deviation between measurements in a sequence
when the object under test is the same and approaches its value from the same direction
each time. The measurements have to be made under a short enough time duration so
as not to allow significant long-term drift. Repeatability is usually specified as a
percentage of the sensor range.
Reproducibility is the same as repeatability, except it also incorporates long time
lapses between subsequent measurements. The sensor has to be operated between
measurements but must be calibrated. Reproducibility is specified as a percentage of
the sensor range per unit of time.
Sensor selection:
The system proposed must ensure that it can sort products based on both their shapes
and their heights. Therefore, here then chosen sensor is the photoelectric sensor
OMRON E3F3, used for optical proximity measurement.

31 | P a g e
 Figure 1.28 OMRON E3F3

Figure 1.29 OMRON E3F3 Datasheet

1.2.8 Programmable Logic Controller

Programmable Logic Controller (PLC) is different from the normal controller
having only one specific controlling algorithm. PLC can freely change the algorithm as
the user’s needs, which allows PLC flexibly to fulfill any requirements.

32 | P a g e
 Figure 1.30 Programmable Logic Controller (PLC)
PLC is a better choice than relay system or standard computer due to the following
reasons:
• Saving space: a PLC needs less space than a standard computer or a relay control
box, with the same purposes;
• Saving energy: PLC consumes energy at really low level, compared to standard
computers;
• Low cost: a PLC costs approximately about 5 to 10 relays, but PLC can replace
hundred of relays;
• High adaptability to industrial environment: The housing of PLC is usually made
of hard material, which can withstand contaminants, moisture, vibrations, and
noises;
• Direct interface: Standard computers need a complex system to be interacted with,
while, PLC can be directly controlled with the I/O modules;
• Easy to program: Most of the PLCs use the programming languages having
trapezoidal diagrams, which are identical to common relay control systems;
• Highly flexible: The control program of PLC can be modified quickly and easily,
using flash memory cards or network transmission.
PLC also has some disadvantages, such as:
33 | P a g e
 • The non-standardized programming language: Each manufacturers have their own
language making it harder for the users;
• Considering small-scale control circuits, PLC costs more than the methods using
relay.

1.2.9 Relay
In electronics, a relay is an electrically operated switch that uses an electromagnet
to mechanically open or close a set of contacts. When an electrical current is applied to
the relay's coil, it creates a magnetic field that pulls a metal armature towards the coil,
causing the contacts to either open or close. Relays are commonly used in circuits to
control high-voltage or high-current devices with low-voltage signals, such as in
automotive applications, industrial control systems, and home automation systems.

Figure 1.31 Relays

The principle of electronic relay is that it uses a small amount of electrical energy
to control a larger amount of electrical energy. This is achieved using an electronic
switch, which is activated by a small current flowing through a control circuit. The
switch then allows a larger current to flow through the output circuit, which can be used
to control the operation of other devices in the circuit. The electronic switch is typically
made up of a transistor or a solid-state relay, which provides fast switching times and
high reliability compared to traditional mechanical relays.
In this project, the chosen relay model is MY2NJ from OMRON, having:
• The coil’s voltage: 24VDC;
• Contact points: 5A – 24VDC.

34 | P a g e
 1.3 System 3D Model
1.3.1 Conveyor Frame
As presented above, all the frameworks in this project are designed to be made of
extruded aluminum bars, with the standard maximum length of each bar being 1000
(mm). The use of aluminum bars makes it easier to transport the system from place to
place and makes it more useful in most cases, we can simply add more bars or more
mechanisms into the existing systems without any welding work.

Figure 1.32 The Conveyor Frame 3D Model

1.3.2 Conveyor Belt

We selected the belt as PVC type. This selection has some advantages, there is
minimum noise when the system is operated, easier to clean, and the coefficient of
friction between PVC and the items’ material is typically higher than with smooth (or
knurled, grated) metal surface.

35 | P a g e
 Figure 1.33 The PVC Belt 3D Model

1.3.3 Motor
The selected motor has a standard gear-drive built-in with the transmission ratio
utv = 10; the working power Pdc = 25 (W); the output speed of the motor with the gear-
drive is 50 (rpm).

Figure 1.34 The Motor with Built-in Gear-drive 3D Model

36 | P a g e
 1.3.4 Chain Drive
The external transmission used in this project is a chain drive.

Figure 1.35 The Large Sprocket 3D Model

Figure 1.36 The Small Sprocket 3D Model

37 | P a g e
 1.3.5 3D Model of the Product Sorting System
A full operating cycle is executed as follows: The product sorting system starts,
then the items are dropped into place by the vibrating feeder with 4 items stacking on
each other. The cylinder at the feeder position pushes the items to be spaced evenly 250
mm, and the system starts classifying. Firstly, the first sensor (counting from the feeder
side), which is placed 100.5 (mm) above the conveyor belt surface, will detect any items
with 100 (mm) height to push down the first conveyor slide. With the same method, the
next sensors are placed above the conveyor belt 70.5 (mm); 50.5 (mm) to detect any 70
(mm) or 50 (mm) height item, respectively. Here, we have three specific item types with
the same height at 30 (mm), which are two cube items and one cylindrical item.
Considering two cubes are different from each other in colors. To classify these three
item types left, we use sorting sensors to detect the differences in shape and in color.
Then, two of them will be pushed into the last 2 conveyor slides and the last one drops
out at the end of the belt.

38 | P a g e
 Figure 1.37 The Final 3D Model of the Product Sorting System
1.4 System Control Charts

Figure 1.38 The General Control Chart

39 | P a g e
 Figure 1.39 The General Control Chart

40 | P a g e
 CHAPTER 2. CONTROL SYSTEM CONFIGURATION

2.1 Control Principle

2.1.1 Operational Block Diagrams
The system’s operation can be executed under two different modes, MANUAL
and AUTO (as shown in Figure 2.1) MANUAL basically stands for manual operations
including separate steps, controlled by multiple buttons, switchs, and sensors. On the
other hand, in AUTO mode, the control decisions are automatically made by the
control program, based on the signal of the sensors.

Figure 2.1 General Block Diagram

41 | P a g e
 Figure 2.2 shows the simplified layout of the system.

Figure 2.2 The Simplified System’s Layout

2.1.2 MANUAL Mode’s Principle

In details, the MANUAL mode’s operation consists of the following processes
(displayed in Figure 2.3):
• Pressing START button, the green LED is turned on, indicating the operation has
started: the conveyor belt’s motor starts to run;
• The feeder’s sensor starts to response. If there is no signal, meaning there are no
items in the feeder, the conveyor belts’s motor will stop in a short delay.
Otherwise, the motor keeps running;
• Pressing START button, the feeder’s cylinder pushs an item onto the conveyor
belt, then, the item will be delivered to the first sorting sensor (h = 10 mm) at S1
(presented in Figure 2.2);
• If sensor at S1 is activated, the conveyor belt’s motor stops;
• Pressing START button, the cylinder at S1 pushes the identified item (with h = 10
mm) into the corresponding rack and storing unit. Consequently, the couting
sensor at S1 adds one to the number of counted items (+1);
• If the S1 sensor is not activated, the conveyor belt’s motor keeps running to S2.
Here, if the sensor S2 is activated, the motor stops;

42 | P a g e
 • Pressing START button, the cylinder at S2 pushes the identified item (with h = 7
mm) into the sorting tray and storing unit. Consequently, the counting sensor at
S2 (+1);
• If the S2 sensor is not activated, the conveyor belt’s motor keeps running to S3.
Here, if the S3 sensor is activated, the motor stops;
• Pressing START button, the S3 cylinder pushs the identified item (with h = 5 mm)
into the sorting tray and storing unit. The counting sensor +1;
• If the sensor S3 is not activated, the conveyor belt’s motor keeps running to S4.
Here, the counting sensor +1 and the item is kept being delivered to the S4 storing
unit;
• The sorting process repeats for the following item.

Figure 2.3 The Simplified System’s Layout

43 | P a g e
 2.1.3 AUTO Mode’s Principle
For the AUTO mode, the processing steps are akin to MANUAL mode with
additional automated decisions (displayed in):
• Pressing START button, the green LED is turned on, indicating the operation has
started: the conveyor belt’s motor starts to run;
• The feeder’s sensor starts to response. If there is no signal, meaning there are no
items in the feeder, the conveyor belts’s motor will stop in a short delay.
Otherwise, the motor keeps running;
• After checking whether having any items in the feeder, in a short delay, the
feeder’s cylinder will push an item onto the conveyor belt. Then, the conveyor belt
delivers the item to S1;
• If the S1 sensor is activated, the conveyor belt’s motor stops. Consequently, the
S1 cylinder will push the identified item (with h = 10 mm) onto the S1 sorting tray
and storing unit, then, the S1 counting sensor +1. If the S1 sensor is not activated,
the conveyor belt’s motor keeps running to S2;
• If the S2 sensor is activated, the conveyor belt’s motor stops. Consequently, the
S2 cylinder will push the identified item (with h = 7 mm) onto the S2 sorting tray
and storing unit, then, the S2 counting sensor +1. If the S2 sensor is not activated,
the conveyor belt’s motor keeps running to S3;
• If the S3 sensor is activated, the conveyor belt’s motor stops. Consequently, the
S1 cylinder will push the identified item (with h = 5 mm) onto the S3 sorting tray
and storing unit, then, the S3 counting sensor +1. If the S3 sensor is not activated,
the conveyor belt’s motor keeps running to S4;
• When one of the storing units is full, the red light representing that storing unit
will be turned on. The conveyor belt’s motor stops, allowing the replacement of
the full unit with an empty one;
• Pressing STOP button to stop the operation at the exact moment;
• Pressing RESET button to get the system back to operation.

44 | P a g e
 Figure 2.4 The Automatic Mode Control Chart

2.2 Electric Components Selection

2.2.1 LED Indicator Lights
Selecting the common type of indicator lights, having the following specification:
• Model: AD16-22DS (as shown in Figure 2.4);
• Mouting size: 22 mm;
• LED voltage: 24 V;
• Rated current: ≤ 20 mA.

45 | P a g e
 Figure 2.4 AD16-22DS LED Indicator Lights]
This indicator light model is reasonably low-cost, easy to install, and has high
brightness. Widely used in electric power, telecommunications, machine tool, motor,
home with long-life and high reliability.

2.2.2 Push Buttons

For push buttons, the most popular type is spring return push button, and the
commonly selected model is LA38, having the following specification:
• Model: LA38 (as shown in Figure 2.5);
• Mounting size: 22 mm;
• Max. voltage: 440 V;
• Max. current: 10 A;
• Contact type: 1NO 1NC.

Figure 2.5 LA38 Spring Return Push Buttons

46 | P a g e
 2.2.3 Emergency Stop Buttons
Selecting the emergency stop button, having the same push mechanism as the
push buttons with an additional self-locking system (as shown in Figure 2.6):
• Model: LA38-11ZS;
• Mounting size: 22 mm;
• Max. voltage: 440 V;
• Max. current: 1 A;
• Contact type: 1NO 1NC.

Figure 2.6 LA38-11ZD Spring Back with Self-locking Push Button

2.2.4 Rotary Switch for MANUAL/AUTO Running Mode

Selecting the rotary switch for shifting the operation mode between MANUAL
and AUTO, having the following specification Model: LA38-11 (displayed in Figure
2.7);
• Mounting size: 22 mm;
• Max. voltage: 400 V;
• Max. current: 10 A;
• Contact type: 1NO 1NC.

47 | P a g e
 Figure 2.7 LA38-11 Rotary Switch for MANUAL and AUTO Mode

2.2.5 Proximity Sensors

Selecting the most common type of photoelectric sensors for heigth sorting, whose
model is E3F3 from OMRON (presented in Figure 2.8), having the specifications shown
in

Figure 2.8 OMRON E3F3 Photoelectric Sensor

48 | P a g e
 Table 1.4 The Specification of OMRON E3F3 Photoelectric Sensor

2.2.6 General Purpose Relays

Selecting the MY2N DC24 model for the relays, having the following
specification Coil ratings: 24 VDC, 36.3 mA;
• Contact rated load: 5 A – 250 VAC/30VDC (resistive load);
• Operating time: 20 ms max (with rated operating power applied, not including
contact bounce);
• Ambient temperature (operating): -55 to 60°C (with no freezing or condensation).

Figure 2.9 OMRON MY2N 24VDC General Purpose Relay

49 | P a g e
2.2.7. Controller
Because the system need to withstand the noise in an industry environment so PLC is
our chosen type of controller in this case. For this project, PLC S7-1200 1212
DC/DC/DC is chosen

Figure 4.12 Simatic S7-1200, CPU 1212C, DC/DC/DC.

Information of SIMATIC S7-1200, CPU 1212C, compact CPU, DC/DC/DC: onboard
I/O: 8 DI 24 V DC; 6 DO 24 V DC; 2 AI 0-10 V DC, power supply: DC 20.4-28.8 V
DC, program/data memory 100 KB.

In this project we need 8 digital output and 6 digital output. Because we want to
isolate the controller from noise make by other “big” component of the system (motor,
pneumatic system) so we use a PLC with DC source so we can use a separate power
source. Also based on the type of sensor and relay we use, we need the PLC with DC
input and output.

50 | P a g e
 CHAPTER 3. CONTROL PROGRAM AND DIAGRAMS

3.1 Control Program Specifications

3.1.1 Inputs and Outputs
The system’s operation includes the following input tags (as shown in Figure 3.1):
1. Operation mode selection;
2. Product height sensor h = 10;
3. Product height sensor h = 7;
4. Product height sensor h = 5;
6. Turn on/off conveyor motor;
7. Turn on/off cylinder h = 10;
8. Turn on/off cylinder h = 7;
9. Turn on/off cylinder h = 5.

Figure 3.1 PLC Main Input Tags

and the following output tags in Figure 3.2:
1. Automatic mode indicator;
2. Manual mode indicator;
3. Conveyor motor;
4. Cylinder h = 10 signal;
5. Cylinder h = 7 signal;
6. Cylinder h = 5 signal.

51 | P a g e
 Figure 3.2 PLC Output Tags
with two intermediate tags (as presented Figure 3.3) for simulation mode and reset all
counters.

Figure 3.3 PLC Intermediate (Middle) Tags

3.1.2 PLC Program Blocks

The PLC program in this project consists of 5 blocks as in Figure 3.4, consisting
a main block (MAIN) and 4 function blocks (FC).

Figure 3.4 PLC Program Blocks

52 | P a g e
 The main block is used to control all the primary features of the PLC program,
having the following networks (as shown in Figure 3.5):
• Shifting between operation modes (manual/automatic) by switching the
indicators;
• Running automatic operation mode when the indicator is on;
• Running manual operation mode when the indicator is on;
• Running simulation when the reset button is pressed;
• Calling the outputs.

53 | P a g e
 Figure 3.5 Network of Main Program Blocks
The output functional block consists the networks of the system elements, as the
conveyor and the cylinders (in Figure 3.6):
• Activating the conveyor when the intermediate tag is on and the equivalent
indicator is on, for both cases of manual and automatic;
• Activating the valves controlling the cylinders (h = 10, 7, and 5 simultaneously)
when the intermediate tag is on, also for both cases of manual and automatic
operation.

54 | P a g e
 Figure 3.6 Network of the Output Functional Block
The manual functional block is used for activating the intermediate tags of the
manual mode (Figure 3.7):
• Turn the conveyor motor on when the switch is on;
• Activate the cylinders when the equivalent switchs are on (for h = 10, 7, and 5).

55 | P a g e
 Figure 3.7 Network of the Manual Operation Functional Block

56 | P a g e
 Next program block to be considered is the automatic operation functional block,
including the reset function, automatic operation for the conveyor motor, the cylinders
and the sensors (as listed in Figure 3.8 and Figure 3.9):
• Reset all the counters when the reset button is pressed (Figure 3.8);
• Operating the conveyor motor with set and reset commands. When the cylinders
are retracted, changing bit from 1 to 0 by N_TRIG, the motor continues to
operate for the next product. For sorting purposes, the conveyor has to be stopped
when the sensors are activated, changing bit from 0 to 1 by P_TRIG;
• The cylinders can be operated somewhat the same idea using P_TRIG, as the
conveyor motor. When one of the height sensors (h = 10, 7, and 5) is activated,
the equivalent cylinder is set to active. Moreover, in order to avoid colliding,
after each activation, the cylinder is set to a delay state (here the delay is set as 3
seconds for initial simulating processes) before reset;
• The counters are used under the same method using P_TRIG. When one of the
height sensors is on, the counter will add one (+1) to the counting.

Figure 3.8 Reset Network of the Automatic Operation Functional Block

57 | P a g e
58 | P a g e
59 | P a g e
 Figure 3.9 Operating Networks of the Automatic Functional Block
Finally, the simulation functional block. Here, a position tag is used to simulate
the process. Every system clock tick, as in Figure 3.10, the product will move one unit
on the equivalent axis. Then, if the product reaches the position that the one of the
sensors is activated, the position tag will be reset to “0”.
60 | P a g e
 Figure 3.10 Network for Simulating the Sorting Process as the Movement of the
Product on the Conveyor
The triggering of the sensors is done by considering the position of the product on
the conveyor based on the value of position tag, as shown in Figure 3.11, for all the
product heights. The position of the sensors is specified, until the position value reaches
this specified level, the position will continuely be added one (+1).

61 | P a g e
62 | P a g e
 Figure 3.11 Network for Simulating the Sensor Activations

3.1.3 The Simulation Program Interface in TIA Portal V16

Initially, as shown in Figure 3.12 the program interface starts with the manual
operation mode (the manual indicator is active as the yellow light).

Figure 3.12 Simulation Interface in TIA Portal V16 Using SIMATIC Module

63 | P a g e
 As stated above, the switches at the cylinders and the conveyor motor position can
be used to manually operate the elements. Specifically, as demonstrated in a, the switch
of cube h = 7 is on, activating the cylinder stroke. Furthermore, b, showed that the
conveyor motor switch is on, activating the motor and the conveyor belt.
Turn the simulation switch on and change the operation to automatic mode, the buttons
for the sorting features appear. Pressing one of the buttons will start a sorting simulation
for the equivalent height, for example, the h = 5 button is pressed, the conveyor carries
the product to the h = 5 sensor, then, the conveyor motor stops and the cylinder stroke
extends to push the identified product into the container, then the counters at the sensor
and the container add 1 unit.

3.2 Control System Diagrams

3.2.1 The Component Connection Diagram
The PLC connection diagram is presented as Figure 3.13.

Figure 3.13 PLC Connection Diagram.

64 | P a g e
 CHAPTER 4. CONCLUSION

This chapter concludes the process of delivering the Product Sorting System model,
from concept and ideas, mechanisms, selections and calculations. Despite consulting
technical literature, the student who proposed this project may have not fully grasped a
number of areas of general knowledge. As a result, when executing the project
"PRODUCT SORTING SYSTEM", it is inescapable that restrictions and flaws occur.
Therefore, the student is looking forward to hearing critical feedback and the support of
professors and instructors.

65 | P a g e
ACKNOWLEDGEMENT
I would like to express my gratitude to the lecturers at the School of Mechanical
Engineering, particularly Ph.D.Hoang Hong Hai who has energetically directed,
established suitable conditions, and provided us with significant knowledge for the
completion of this topic project.

66 | P a g e
REFERENCES
[1] Pfaff, F., Baum, M., Noack, B., Hanebeck, U. D., Gruna, R., Langle, T., &
Beyerer, J. (2015). Tracksort: Predictive tracking for sorting uncooperative bulk
materials. 2015 IEEE International Conference on Multisensor Fusion and
Integration for Intelligent Systems (MFI).
https://doi.org/10.1109/mfi.2015.7295737.
[2] System Sortowania Pustych butelek pod WZGLĘDEM WYSOKOŚCI. Vekamaf.
(2021, January 12). Retrieved February 18, 2023, from
https://www.vekamaf.pl/urz%C4%85dzenia/system-sortowania-pustych-butelek-
pod-wzgledem-wysokosci/.
[3] Rotating trays weight grader YGW-YP170/200/250/330F8 (F10). Easyweigh.
(2022, August 5). Retrieved February 18, 2023, from https://www.easyweigh-
group.com/products/rotating-trays-weight-grader/.
[4] Traceability & Quality Control. VisionID. (n.d.). Retrieved February 18, 2023,
from https://visionid.ie/solutions/vertical/manufacturing/traceability-quality-
control.
[5] Pop-up Sorter & Strip Belt Sorter Conveyor System. Conveyco. (2020, October
26). Retrieved February 18, 2023, from
https://www.conveyco.com/technology/sortation-systems/pop-up-sorter-and-
strip-belt-sorter-conveyor/.
[6] Falcon Autotech Pvt Ltd: MSME B2B portal. Falcon Autotech Pvt ltd | MSME
B2B Portal. (n.d.). Retrieved February 18, 2023, from
https://www.msmemart.com/member/product/105695/94253/linear-arm-sorter.
[7] Pusher sorter for low speed sorting of carton, cases, totes and Crates. Falcon
Autotech. (2022, April 12). Retrieved February 18, 2023, from
https://www.falconautotech.com/pusher-sorter/.
[8] Tilt Tray Sorter System: Tilt Tray Sortation Systems 24000 sorts/hr. Falcon
Autotech. (2022, October 7). Retrieved February 18, 2023, from
https://www.falconautotech.com/tilt-tray-sorter/.

67 | P a g e