MEX 6270 70760020

Factory Automation(Assi03) Page 1

A quality control system for wall tile company
Task ,
A wall tile manufacturer has decided to improve the quality of their 6and 8production
line by installing an automatic system to inspect the quality of each tile on the conveyor before
they are packaged. The quality parameters that need monitoring are the length, width and the
weight of each tile. The conveyor may carry either 6or 8 tiles in batches at the rate of one tile
every two second. The tolerance allowed for either length is 2.0mm and for the weight is 25g
(variation in weight indicates defects in density and thicknesses of tile, also same tolerance are
applicable to both types of tiles). If a tile fails any of these tolerances, it has to be ejected from
the conveyor belt by means of some actuators before it reaches the packaging station.

Design,
The following rough drawing shows my desing for the given task. It consists of 4
Photoelectric sensors & one load cell & appropriate conveyers.


A,B,C,D - Photoelectric sensors
E - load cell
P - Pneumatic single acting cylinder.
MEX 6270 70760020

Factory Automation(Assi03) Page 2


Arrows shows the running direction of these conveyers. 5 ft long & 1ft width each
conveyer. They run by geared motors & it ( the conveyer) can stop at pre defined positions .

Procedure,
(01) The tile come through the conveyer 1 & stop at the position that the A,B sensors
situated. It sense the width of tile and check whether 8 tile or 6 tile . then check
the variance of each tile width from expected width.
(02) Then that tile come to conveyer 2. When its moving to conveyer 2 ,conveyer 2
remain stop.
(03) Then tile come to E load cell position, & check the width of other side by C,D
sensors and measure the weight of it.
(04) If any of this measuring aware from expected values. Activate the pneumatic
cylinder and reject the tile.

Assumptions,
(01) Tiles come one by one & have 300mm gap with each tile
(02) Tiles come on center of the conveyer
(03) There are no any excess load apply to the load cell due to the conveyer belt.
(04) Assumed conveyers width 300mm & 900mm long
(05) Assumed tile change to 2
nd
conveyer takes 0.5s .
(06) A tile remain stop at E position .05s
(07) All process take only 2s
(08) No any overlap happen
(09) Conveyers can stop perfect positions


Width calculation for 8 tile,
8= 203mm
Acceptable width=201-204mm
Perpendicular distance for each A,B sensor=300mm
8 tile check ----- 201<=A+B<=204

Same as,
6 tile= 153mm
Acceptable width=151-155

6 tile check--------------146<=A+B<=150


MEX 6270 70760020

Factory Automation(Assi03) Page 3

Flowchart,

























Start
A<160

16000
00000
00000
00000
00000
A tile arrive


A+B<
=99

A>16
A+B<
=99
6 tile


A>16
8 tile


A>16 95<=A+
B<=99
146<=A+
B<=150
Width OK


A+B<
=99

A>16
Width OK


A+B<
=99

A+B<
=99

A>16
95<=A+
B<=99
14 To
packi
ng
stage
6<=A+B<
=150
Length OK


A+B<
=99

A+B<
=99

A>16
Length OK


A+B<
=99

A+B<
=99

A>16
425<=E
<=475
275<=E
<=325
Weight OK


A+B<
=99

A+B<
=99

A>16
Weight OK


A+B<
=99

A>16
Reject tile

A+B<
=99

A+B<
=99

A>16
To packing
stage


Width OK

A+B<
=99

A+B<
=99

A>16

A+B<
=99

A+B<
=99

A>16
To packing
stage


Width OK

A+B<
=99

A+B<
=99

A>16

A+B<
=99

A+B<
=99

A>16
MEX 6270 70760020

Factory Automation(Assi03) Page 4

Instruments,
(01) 21M-LA02-S92 photoelectric sensors -4
(02) XLP 58 package load cell, integrated with internal amplifier (output 0-5v)
(03) 300mm long pneumatic single acting cylinder
(04) Appropriate conveyers
(05) Appropriate mounting mechanism.
(06) Seimens S7-200 PLC ( For this circuit dont want such a multipurpose PLC it can
control by PIC or other microcontroller , but most companies try to use most
available , easy to program & very expensive items( ex:- NIKINI Automation)
Because clients dont know about the technology)


In here I didnt do programming part for our design. It should be done when implementing
. relevant data sheets of the instruments attached to the assignment.

Load cell data sheet


MEX 6270 70760020

Factory Automation(Assi03) Page 5



Sensor datasheet,