20EI663 Process Control and Automation Event-4

Advanced PLC Programming for

Defective Parts Sorting
Submitted to
Sanjana AS
Prof. Anusha M U
Shruthi Assistant Professor
Vaishnavi C Department of ELECTRONICS AND INSTRUMENTATION
Yashwanth Dillikar JSS Science and Technology University [JSSSTU]
2023-24
 INTRODUCTION

• Programmable Logic Controllers (PLCs) play a crucial role in industrial automation,

including the sorting of defective parts in manufacturing processes.
• By using PLCs for defective part sorting, manufacturers can efficiently identify and
divert faulty components, ensuring product quality and minimizing production waste.
• Advanced PLC programming for defective parts sorting to distinguish between good and
bad parts and then transport them via conveyors.
• The conveyors are used to move the products. The conveyors are started and stopped
when the products are delivered on the conveyor and during the drilling operation.
• The drill machine is used for drilling the products as per the design. Sometimes the
drilling operation may damage the products
• A sensor detects the quality of the products and a pusher is used to push the bad products
into another storage bin.
PLC Inputs and Outputs
Type Device No. Device name Operation

Input XO Drilling ON while drilling

Input X1 Part under Drill One part is supplied

when Y0 is ON: A large
metal cube.

Input X2 Drilled correctly ON when the part is

drilled correctly. The
previous result is
cleared when drilling
starts.
Input X3 Drilled wrong ON when the part is
detected at the left end.
Input X4 sensor ON when the part is
detected at the right
end.
 ON when the part is
Input X5 Sensor detected in front of the
pusher.
ON when the part is not
drilled correctly. The
Input X10 Sensor previous result is
cleared when drilling
starts.

Output Y0 Supply command The conveyor moves

forward when Y1 is ON.

The conveyor moves

Output Y1 Conveyor forward forward when Y3 is ON.

Starts drilling when Y2 is

ON (A process cycle that
Output Y2 Start drilling cannot be stopped
partway).
 Extends when Y5 is ON
and retracts when Y5 is
Output Y3 Conveyor forward OFF. The pusher cannot
be stopped in the mid-
stroke.
Extends when Y5 is ON
and retracts when Y5 is
Output Y5 Pusher OFF. The pusher cannot
be stopped in the mid
stroke.
Program Description
This project aims to differentiate between good and defective parts using
sensors and sorting them accordingly. The project consists of two key areas:
overall control and drill control.
• Overall Control

There is a pushbutton named PB1 (X20) on the control panel. When you
press PB1, it triggers the Supply command (Y0) for the hopper, causing it
to supply parts. Releasing PB1 deactivates the Supply command, stopping
the hopper.
There is a switch, SW1 (X24), on the control panel. When you turn SW1
ON, the conveyors start to move forward. Turning SW1 OFF halts the
conveyors.
• Drill Control
Now let’s discuss the control of the drill:
When the Part under the drill sensor (X1) within the drill is activated, the conveyor
halts. The drilling process commences when the Start drilling command (Y2) is
activated. It stops when the Drilling sensor (X0) is activated. After one complete
cycle of drill operation, if Start drilling (Y2) is activated, either the Drilled correctly
(X2) or Drilled wrong (X3) sensor is triggered. Note that the drill can’t be stopped
mid-operation. In this PLC simulation, every third part is considered defective (A
part with multiple holes also falls into the defective category).
When the Detect part sensor (X10) in the pusher identifies a defective part, the
conveyor stops, and the pusher moves the part onto the ‘Defective’ tray. Remember
that when the actuating command for the pusher is ON, it fully extends. When the
command is OFF, the pusher fully retracts. A part that passes inspection continues
along the conveyor to the ‘OK’ tray located at the right end.
PLC Programming
Advantages
• Efficiency: PLCs enable fast and accurate detection of defective parts, leading to
efficient sorting and minimal disruption to the production line.
• Reliability: PLCs are known for their reliability in industrial environments,
ensuring consistent performance in defect sorting operations.
• Customization: PLC programs can be easily customized to accommodate different
types of defects and sorting requirements, providing flexibility in manufacturing
processes.
• Data Logging: PLCs can log data on detected defects, sorting actions taken, and
system performance, allowing for analysis and optimization of the sorting process.
• Integration: PLCs can seamlessly integrate with other automation systems, sensors,
and equipment on the production line, creating a cohesive and efficient
manufacturing environment.
Disadvantages
• Initial Cost: Implementing a PLC system for defective part sorting can
involve significant upfront costs for hardware, software, and integration
with existing equipment.
• Complexity: Programming PLCs for defect sorting requires specialized
knowledge and skills, which may pose a challenge for some
manufacturers without prior experience.
• Maintenance: PLC systems require regular maintenance, updates, and
troubleshooting to ensure optimal performance, adding to the overall
operational costs.
• Downtime: In the event of PLC malfunctions or programming errors,
there may be downtime in production while troubleshooting and
resolving issues.
Future scope
As technology continues to advance, the future scope of using Programmable Logic
Controllers (PLCs) for defective part sorting holds promising opportunities for further
improvements in manufacturing processes. Here are some potential future
developments and trends in this area:
• Artificial Intelligence Integration: The integration of artificial intelligence (AI)
algorithms with PLC systems could enhance defect detection capabilities, enabling
more sophisticated analysis of defects and automated decision-making in sorting
processes.
• Machine Learning Applications: Implementing machine learning models within
PLCs could enable predictive maintenance, adaptive sorting algorithms, and
continuous optimization of defect sorting based on historical data and real-time
feedback.
• Internet of Things (IoT) Connectivity: Connecting PLCs to IoT devices and
sensors could enable remote monitoring, data sharing, and predictive analytics,
enhancing overall efficiency and performance in defective part sorting operations.
• Industry 4.0 Integration: PLCs are expected to play a crucial role in the
implementation of Industry 4.0 principles, including cyber-physical systems, cloud
computing, and real-time data exchange, leading to more interconnected and
intelligent manufacturing ecosystems.
• Robotics Collaboration: Collaborative robots (cobots) working in tandem with PLC-
controlled sorting systems could further automate defect detection and sorting tasks,
improving overall productivity and quality control in manufacturing environments.
• Augmented Reality (AR) Assistance: AR technologies integrated with PLC
interfaces could provide operators with real-time visual guidance, instructions, and
feedback during the sorting process, enhancing efficiency and reducing human errors.
• Energy Efficiency Solutions: Future PLC developments may focus on energy-
efficient sorting mechanisms, optimized control algorithms, and sustainability
initiatives to reduce energy consumption and environmental impact in manufacturing
operations.
Conclusion
In conclusion, utilizing PLCs for defective part sorting offers numerous
advantages in terms of efficiency, reliability, customization, data logging,
and integration within manufacturing processes. While there are some
drawbacks such as initial costs, complexity, maintenance requirements,
and potential downtime, the benefits of implementing PLCs for defect
sorting outweigh the challenges. By carefully designing and
programming PLC systems, manufacturers can enhance quality control,
minimize waste, and improve overall production efficiency in the long run.
With proper planning, training, and maintenance, PLCs can be a valuable
asset in ensuring product quality and streamlining defect sorting processes
in industrial settings.
Thankyou