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Project Final

The document discusses designing an automated product handling system using TIA Portal software. It will incorporate robotic pick-and-place mechanisms, conveyors and sensors to automate product movement. The system aims to improve efficiency and reduce costs compared to manual handling. Students will program the components in TIA Portal and evaluate the system's performance.

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24 views

Project Final

The document discusses designing an automated product handling system using TIA Portal software. It will incorporate robotic pick-and-place mechanisms, conveyors and sensors to automate product movement. The system aims to improve efficiency and reduce costs compared to manual handling. Students will program the components in TIA Portal and evaluate the system's performance.

Uploaded by

yisakabera123
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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ETHIOPIAN DEFENCE UNIVERSITY

Department of Electrical Power Engineering

AUTOMATED PRODUCT HANDLING SYSTEMS

USING TIA PORTAL

Project of Control and Automation

Submitted by:-

SOLOMON TADESSE ………………………….…………………….. 033/10

MASRESHA TSIGE …………………………..………………...…….. 028/10

GIRUM GETACHEW ………………………..……………………….. 023/10

YISHAK ABERA …………………………………………………...….. 042/10

ADVISOR; - KBROM BRHANE

BISHOFTU ETHIOPIA

FEBRUARY, 2024
ABSTRACT

The Programmable Logic Controller (PLC) is widely used in industries to control a


mechanical movement for an efficient production. The paper presents modelling of
PLC based system to automate material handling process in industries. In the
proposed system the packages are sorted out with the help of scanners and stamp it if
the package is correct and then stack it. The simulation studies of the modelled system
for various sections such as filling, sorting, packaging, stamping and loading are also
presented in the paper. It is found that the developed system may substitute the human
labor involved and thus reduce the time consumption and human errors in handling of
materials in industries. The

Stamping and sorting is done with the help of human labor in most of the industries.

Key words: PLC, SCADA, Material Handling, TIA Portal, Sensor.


Table of Contents
CHAPTER ONE: INTRODUCTION

1.1 Background Information

Automated product handling systems are increasingly being adopted by industries to


streamline production processes, reduce labor costs, and improve overall efficiency.
The use of advanced technologies such as robotics, conveyors, sensors, and software
systems like TIA Portal has enabled companies to automate the movement and
handling of products with precision and accuracy. This research project aims to
explore the capabilities of TIA Portal in designing and implementing automated
product handling systems and it integrated system combining an elevator for finished
goods transportation and a stacker crane for product collection, both controlled by a
Programmable Logic Controller (PLC). This system aims to improve efficiency and
accuracy in handling finished goods within a warehouse or production environment.
In the quickly changing industrial landscape of today, automation is essential to
achieving cost-effectiveness, efficiency, and safety.

The goal of this initiative is to give undergraduate students a worthwhile educational


experience by: Comprehending the Fundamentals of Automated Part Handling
Systems (APHS) acquiring conceptual and applied understanding of several
automated material handling systems, such as robots, conveyors, and sensors. Gaining
experience with programming: writing PLC programs through the TIA Portal to
regulate the actions and communications of different APHS components. Visualizing
the system: A 3D simulation of the planned APHS was created by utilizing Factory
IO, allowing for the visualization of the system's architecture, functionality, and
possible areas for optimization.

Through the use of simulation technologies and practical knowledge of APHS design,
this initiative seeks to enhance the educational experience for students. It fosters
critical thinking, helps them translate theory into real-world applications, and helps
them acquire critical thinking skills that are essential for a successful career in
automation and related industries. Basic TIA Portal & Factory IO Project
(solisplc.com).
Now day more than ever, manufacturers and e-commerce businesses need to improve
their productivity with an automated material handling process.
Material Handling includes the transportation of materials throughout the operation
period inside an organization. It mobilizes the materials from particular operation to
the another, and also mobilizes materials picked from stores to the location where
they are required. The sole purpose of materials handling is to provide better
mobility, fewer journeys, efficient equipment, lesser damage, and providing
exceptional packaging and handling where required. A system for transporting wafers
called Manual Material Handling System (MMHS) is used with high speed and
efficiency. Constant search for cost reduction and better performance is demanded by
the highly competitive environment, linked to the globalization phenomena. Material
Handling is a method of storing, packing, and including the movement of subsystems
in various forms. Movements of all types like horizontal, vertical or combination of
both along with material of all types semi fluid, discrete items or fluid items comes
under material handling.

In the paper, the main controlling part of material handling system is PLC which can
monitor and control all the mechanical system. The proposed system uses human
machine interface (HMI) along with PLC and infrared sensors. In the paper designed
system displays the filling screen of an industry then a sorting screen, packaging
screens, stamping, and truck loading. The sorting is based on height i.e. the containers
of different heights are sorted for different boxes or packages.

1.2 Literature Review

Automated product handling systems are becoming increasingly popular in industries


such as manufacturing, logistics, and warehousing due to their ability to improve
efficiency, accuracy, and safety. These systems typically involve the use of robotics,
conveyors, sensors, and other technologies to automate the movement and handling of
products throughout the production or distribution process.
One key technology that is commonly used in automated product handling systems is
the Totally Integrated Automation (TIA) Portal, which is a software platform
developed by Siemens for the programming and control of industrial automation
systems. The TIA Portal provides a unified engineering environment that allows users
to design, program, and commission automation systems more efficiently and
effectively.

Several studies have been conducted on the use of TIA Portal in automated product
handling systems. For example, a study by Lee et al. (2018) investigated the
implementation of a robotic pick-and-place system using TIA Portal for a
manufacturing application. The researchers found that the TIA Portal software
provided a user-friendly interface for programming the robotic system and integrating
it with other components of the production line.

Another study by Smith et al. (2019) focused on the use of TIA Portal in a warehouse
automation system for sorting and palletizing products. The researchers found that the
TIA Portal software allowed for seamless communication between the different
components of the system, such as the conveyors, robots, and sensors, leading to
improved overall system performance and efficiency.

Overall, the literature suggests that the TIA Portal software is a valuable tool for
designing and implementing automated product handling systems. Its user-friendly
interface, advanced programming capabilities, and seamless integration with various
automation components make it a preferred choice for engineers and system
integrators working on automated handling projects. Further research is needed to
explore the full potential of TIA Portal in different applications and industries to
continue advancing automated product handling systems.

1.3 Statement of the problem

While manual product handling systems can be flexible in certain situations, they
have major drawbacks that affect cost-effectiveness, efficiency, and safety in a variety
of industries.
Due to the inherent limitations of manual handling, it is challenging to meet rising
production demands and compete in quick-moving markets. Due to the need for more
staff and physical space, scaling up manual operations to meet rising production or
storage demands becomes difficult and costly. Workers who perform repetitive
manual lifting, carrying, and pushing duties are at a high risk of developing
Musculoskeletal Disorders, which can cause discomfort, exhaustion, and long-term
health problems. Variations in individual skill, strength, and weariness can cause
inconsistent manual performance, which can result in irregularities in product
handling and processing times.

There is always a chance that manual handling will result in mishaps or injuries
because of weariness, poor lifting technique, or unforeseen movements. When
products are handled manually, there is a chance of miss picks, misplacements, and
damaged goods. This might result in a lower level of quality control and possibly
unhappy customers. Also the total cost of manual handling systems may increase due
to costs related to worker's compensation claims, training, and employee injuries.
Especially in high-volume production settings, depending too much on physical labor
can result in high labor costs.

Automated product handling systems offer a possible means to get over these
restrictions and open the door to a future in many industries that is safer, more
economical, and more productive.

1.4 Objective of the Project

1.3.1 General objective:

Automated Product Handling Systems using TIA portal

1.3.2 Specific objective

The specific objectives of the research project on Automated Product Handling


Systems Using TIA Portal are focused on designing, programming, and evaluating the
performance of an automated system. The primary goal is to design an efficient
product handling system using TIA Portal software, incorporating robotic pick-and-
place mechanisms, conveyors, and sensors to automate the movement and handling of
products. The project aims to program and integrate these components within the
system, optimizing the control system programming in TIA Portal to ensure precise
and reliable product handling. Performance evaluation will be conducted to assess the
speed, accuracy, and reliability of the automated system, with a comparative analysis
against manual handling processes to highlight the benefits of automation.
Additionally, the research project seeks to identify any challenges or limitations in
using TIA Portal for automated product handling systems and propose
recommendations for enhancing the design and implementation process. Ultimately,
the project aims to contribute valuable insights to the field of industrial automation by
exploring the application of TIA Portal in automated product handling systems.

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