Вы находитесь на странице: 1из 92

FINAL YEAR PROJECT DOCUMENTATION 1

STATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)

CHAPTER 1

PROJECT INTRODUCTION

1.1 INTRODUCTION

Nowadays, Industrial Technology is well known very synonym with automation.


This is because of automation’s reliability and more importantly it does save cost
especially manpower. Thus, our group decides to produce a project that implements
automation in operation process.

In this final year project, specialize in Mechatronics; we are required to produce an


automated machine process base on the chosen product. For our group, we have chosen
stationery merchandise as our product to develop our project, a Stationery Storage and
Retrieval System (SSRS).

These machines have six process sequences which are; initializing I/O card, user
verification, menu selection, item selection, confirm item and collects item. The machine
comes with systems that make it intelligent enough to perform its task with minimum
supervision. Besides, to make it compatible with other machine, the system is complete
with user friendly unlimited items requested (e.g. user can request for any items several
times) and some additional safety features for both; product and the user.

G erman - Mal aysi an I ns ti tu te


Training for Advanced Technology
FINAL YEAR PROJECT DOCUMENTATION 2
STATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)

The SSRS is eventually an ideal method for the lecturer and trainees to acquire or
review basic theoretical and practical knowledge in Mechatronics field. It is a combination
of electrical, electronics, mechanical, PLC and computer programming. Every module is
designed to perform a specific function such as smart storage, loading, inspection and etc.
Standard components such as motors and sensor are integrated into each module to
achieve the desired function.

It is an innovative creation project base on the concept of the vending machine


available in the market nowadays. Thus, this machine is specially designed according to
the needs of office personnel for organizing the usage of stationery merchandise. It will
also help to build up a better management and increased the productivity.

G erman - Mal aysi an I ns ti tu te


Training for Advanced Technology
FINAL YEAR PROJECT DOCUMENTATION 3
STATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)

1.2 OBJECTIVE

1.2.1 MAIN OBJECTIVES

The main objectives of this Final Year Project is to let us gain experience in
designing, electrical wiring, programming and troubleshooting a machine. We also apply
the knowledge learned in GMI especially in the Mechatronics field. The given opportunity is
to change idea with group member and deal with other members to exchange information.

We were also having learned the communication skill when dealing with the
vendors. This is also to expose us to the real working life experience as a project team in
the engineering field.

During the project implementation process, we also have learned to increase


knowledge about machine design and automation element. To manage the project and
have the cooperation among the group members is an important part where without it the
project can’t be done properly. Finally, cooperative with supervisor is also the important
thing where we have to respect him as our guidance since doing this project.

G erman - Mal aysi an I ns ti tu te


Training for Advanced Technology
FINAL YEAR PROJECT DOCUMENTATION 4
STATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)

1.2.2 PROJECT OBJECTIVES

SSRS applies all the knowledge that Mechatronics student gained all through the
previous semester. Furthermore, this project also has advantages that enhance its
specialty. As a result, this machine could help to improve the lifestyle of humanity to
become more organized.

The main objectives of this project are stated as below:

• Designed a machine that can organize the stationery merchandise.


• Developed a system that fully controlled by computer base.
• Developed an efficient office management by equip the latest technology for
monitoring system.
• Improved inventory system and simulate the industrial practices on realistic
industrial system model.

G erman - Mal aysi an I ns ti tu te


Training for Advanced Technology
FINAL YEAR PROJECT DOCUMENTATION 5
STATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)

1.3 PROJECT SPECIFICATION

NAME Stationery Storage and Retrieval System (SSRS)


PRODUCT Stationery merchandise and Office Equipments
Dispense stationery merchandise and improve inventory
FUNCTION
system.
VOLTAGE SUPPLY 220 ~ 240V AC, 2.5 A, 50 Hz
POWER SUPPLY UNIT 5V DC, 12V DC, 24V DC
MACHINE DIMENSION 1000mm x 1000mm x 1950mm (include tower lamp)
1) Limit switch
SENSING
2) Inductive sensor
1) DC Motor (12V DC)
2) Stepper motor
DRIVE SYSTEM
3) Gear
4) Chain
1) Movable Pusher
TRANSFERRING SYSTEM
2) DC Motor (12V DC)
1) Silo
OUTPUT SYSTEM
2) Discharge Section
1) Programmable Logic Control (PLC) SIEMENS
Step 7-200
CONTROLLER 2) Position Module EMS 253
3) Motor Driver
4) PC I/O card
DATABASE SYSTEM Visual Basic 6
OPERATING SYSTEM Manual
1) GREEN for operating region
INDICATOR 2) YELLOW for transferring
3) RED for stop

Table: Project Specification of SSRS.

1.4 FEASIBILITY STUDIES

G erman - Mal aysi an I ns ti tu te


Training for Advanced Technology
FINAL YEAR PROJECT DOCUMENTATION 6
STATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)

Before we propose this project to the project committee, we have started our
feasibility studies on the main problems involved stationery issue in an office management.
The problems were inventory system for stationery and uncontrolled usage of stationery.
We choose Industrial Electronics (IE) department as a reference to gain more information
about that issue.

Diagram 1 : IE Department.

After identified the source of problems and gain information at IE department, we


made a short listed items. The short listed items are the highest demand by user. So, we
choose the most relevant and convenient items to used as the products to our project.

From the list of items, we went to the stationery shop to get the dimension of the
products for a design purpose.

Diagram 2 : Stationery Shop.

G erman - Mal aysi an I ns ti tu te


Training for Advanced Technology
FINAL YEAR PROJECT DOCUMENTATION 7
STATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)

Diagram 3 : Example of stationery items.

We also do some research in Visual Basic programming because this project


involved Visual Basic 6 as the interface for the machine and the database for the
inventory.

Diagram 4 : Learning process for VB programming.

For drive mechanism, we decide to use two stepper motor, four DC motor, pulleys
and belting. But, after propose the project; we were advised to used just one stepper motor
and two DC motor and also during project implementation, there were some problems
occur and we have to change the design from using pulley and belting to using chain and
gear.

G erman - Mal aysi an I ns ti tu te


Training for Advanced Technology
FINAL YEAR PROJECT DOCUMENTATION 8
STATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)

Diagram 5 : Equipments of drive mechanism.

1.5 PROJECT FEATURES

In order to make this project successful, there are several factors should be
considered. This project fulfils these factors by means of profit return in investments. It is
efficient enough to increase the production rate in ways of shorter and constant. The
safety features provided is also secured both user and product harm.

PC I/O CARD

Diagram 6 : PC I/O card and Terminal block for PC I/O card.

The I/O card we are using in this project is EX 94632. This I/O Card is used to send
signal from Visual Basic 6 button to PLC Siemens S7-200. The I/O Card has it own
terminal block to distribute the input and output from either PC or PLC. We install this card
at the PCI Slot. The output trigger from I/O card is 5 Volts, so we need something to switch

G erman - Mal aysi an I ns ti tu te


Training for Advanced Technology
FINAL YEAR PROJECT DOCUMENTATION 9
STATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)

from 5 Volts with 24 Volts. This I/O card has it own code to be programmed in the Visual
Basic 6; we need to configure which code is suitable for Initializing and set ON and OFF.

OPTO-COUPLER

Diagram 7 : Figure of Opto-coupler circuit.

Besides that, this project involves very highly skill in Mechatronics. In example, the
electronic circuit is design and done by ourselves. The electronic circuit contains Opto-
Coupler for switching the voltage from 5 volts with 24 volts. The opto-coupler used to
trigger Programmable Logic Control (PLC) Siemens S7 – 200 from I/O card. The output
from I/O card is 5 volts, so, to trigger the PLC it need 24 volts. Besides, the opto-coupler is
far faster switching compared to relays. That the reason why we used Opto-Coupler.

VISUAL BASIC 6

G erman - Mal aysi an I ns ti tu te


Training for Advanced Technology
FINAL YEAR PROJECT DOCUMENTATION 10
STATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)

Diagram 8 : Visual Basic 6.

Visual Basic 6 is used as the interface for the machine and the database for the
inventory. We decided to do this project with visual basic because of the increasing of the
computer based control lately. We do the research and study the basic programming code
to implement the proposed project. We managed to finish the interface within 3 months of
study. After that we developed it to make it more interesting and finally we learn on how to
communicate from the Visual Basic 6 with Siemens s7-200. Our system consists the
inventory of item has been dispense by user and selection menu for user to choose
stationary items.

SYSTEM COMMUNICATION

Diagram 9 : PPI Cable and Ribbon Cable.

The communication system using in this project is, for PC to PLC programming we
used PPI Cable that is RS 232 to RS 485. For I/O card to Terminal Block we used flat
Ribbon Cable as a connector.

DRIVE MECHANISM SECTION

G erman - Mal aysi an I ns ti tu te


Training for Advanced Technology
FINAL YEAR PROJECT DOCUMENTATION 11
STATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)

STEPPER SECTION

POSITIONING
TABLE

Diagram 10 : Drive Mechanism Section for SSRS.

For the drive mechanism section, the design at first involved 2 stepper motor to
moved it. But, it cause more cost. After discussion, we decided to use only one stepper
motor. So we start to fabricate the drive mechanism which is involving lot of mechanical
movement. The drive mechanism section contains, two power window motor for forward
and reverse of the pusher rod, positioning table to move the pusher rod, chain to move the
positioning table taken from the movement of stepper motor. The design at first used
timing belt, but due to GMI payment policy we cannot use the timing belt. We find the
solution on how to replace it by using chain

STEPPER SECTION

Diagram 11 : Stepper Section of Drive Mechanism Section.

This section is fully designed and fabricated by our group. This section contains
table mounting, stepper motor and drives mechanism. This section is static due to only
gear is moved by stepper to rotate the chain to move the positioning table.

POSITIONING TABLE

G erman - Mal aysi an I ns ti tu te


Training for Advanced Technology
FINAL YEAR PROJECT DOCUMENTATION 12
STATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)

Diagram 12 : Upper and Bottom of Positioning Table.

This positioning table consists of DC Motor, Pusher Rod, Positioning Table, Limit
Switch, Gear and Chain. This section is one of the most important part because the used
of pusher to dispense items. Positioning table is fully designed and fabricated by our own.
We put lot of effort to finish and to align the position of this table.

BEARING FLANGE

Diagram 13 : Bearing Flange of Drive Mechanism Section.


Bearing flange we used is to replace the real bearing flange by fabricate it on our
own. It is to reduce our cost and it is proven save cost. The bearing actually, we attach to
the metal plate by weld them together. Maybe the design is not similar with the real one,
but it has similar function with the real bearing flange.

G erman - Mal aysi an I ns ti tu te


Training for Advanced Technology
FINAL YEAR PROJECT DOCUMENTATION 13
STATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)

MOVABLE MAGAZINE DRAWER

LOCK

GUIDE RAIL

UPPER DRAWER
BOTTOM DRAWER

Diagram 14 : Upper and Bottom movable drawer magazine.

This kind of drawer is fabricated by us with user friendly design. So, it makes the
drawer easy to put in or put out. The drawer contains guide rail attach with bearing in the
middle to smoothing the movement of the rail. At the back of the rail, it has stopper to
prevent the drawer from over limit of the rail. Beside that, the rail also has lock to prevent it
from slide.

THE SIX PROTOCOLS

This machine consists of six sequence of protocol to be complete to get the end
product. This protocol shows the features of this project on the machine:

1) INITIALIZING I/O CARD

G erman - Mal aysi an I ns ti tu te


Training for Advanced Technology
FINAL YEAR PROJECT DOCUMENTATION 14
STATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)

Diagram 15 : Initializing I/O Card

Initializing for I/O card is important because it is to activate the card for the next
operation. Only by activating this card, user can proceed to the verification protocol.

G erman - Mal aysi an I ns ti tu te


Training for Advanced Technology
FINAL YEAR PROJECT DOCUMENTATION 15
STATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)

2) USER VERIFICATION

Diagram 16 : User Verification

Username and password for account verification. It is to retrieve user profile to


activate the system. When the system activated, selection menu will pop-up.

G erman - Mal aysi an I ns ti tu te


Training for Advanced Technology
FINAL YEAR PROJECT DOCUMENTATION 16
STATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)

3) SELECTION MENU

Diagram 17 : Selection Menu

Selection Menu is use to select next protocol. It is contains of Items Menu and
Purchase History. Items Menu is used to select item and Purchase History is used to view
user history profile. Once selection had been made, it will go to the next menu.

G erman - Mal aysi an I ns ti tu te


Training for Advanced Technology
FINAL YEAR PROJECT DOCUMENTATION 17
STATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)

4) ITEMS SELECTION

Diagram 18 : Items Selection

This protocol consist list of items. User can select any items enormously.

G erman - Mal aysi an I ns ti tu te


Training for Advanced Technology
FINAL YEAR PROJECT DOCUMENTATION 18
STATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)

5) CONFIRM ITEMS

Diagram 19 : Confirmation Of Items

Once user had chosen the needed item, system will prompt the user with
confirmation task bar for each item. Finish with the confirmation, then the drive mechanism
will move the positioning table to extend the pusher at selected item magazine. The item
will dispense at silo and discharge section.

G erman - Mal aysi an I ns ti tu te


Training for Advanced Technology
FINAL YEAR PROJECT DOCUMENTATION 19
STATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)

6) COLLECT ITEMS (pic)

Diagram 20 : Collect item

This is the end of the protocol. User may collect their items after completing all the
protocol. Collect items can be made at the discharge section.

CHAPTER 2

PROJECT IMPLEMENTATION

2.1 SYSTEM LAYOUT

The system layout is comprised of four types of machine layout diagram:

1. Assembly drawing
2. Front view
3. Side view
4. Top view

G erman - Mal aysi an I ns ti tu te


Training for Advanced Technology
FINAL YEAR PROJECT DOCUMENTATION 20
STATIONERY STORAGE AND RETRIEVAL SYSTEM (SSRS)

G erman - Mal aysi an I ns ti tu te


Training for Advanced Technology
2.1.1 MACHINE LAYOUT DIAGRAM

ASSEMBLY DRAWING

Diagram 21 : Figure of 3D and actual assembly drawing for SSRS.


FRONT VIEW

Diagram 22 : Figure of 3D and actual front view for SSRS.


SIDE VIEW

Diagram 23 : Figure of 3D and actual side view for SSRS.


TOP VIEW

Diagram 24 : Figure of 3D and actual top view for SSRS.


2.1.2 ELECTRICAL WIRING DIAGRAM

Diagram 25 : Figure of electrical wiring diagram for SSRS.


2.1.3 ELECTRONICS WIRING DIAGRAM

CIRCUIT OPTO CUPLER – (16 bit)

OPTO COUPLER (A5) OPTO COUPLER (B5) OPTO COUPLER (C5)

OPTO COUPLER (D5) OPTO COUPLER (E5) OPTO COUPLER (F5)

OPTO COUPLER (G5) OPTO COUPLER (H5) OPTO COUPLER (I5)

OPTO COUPLER (J5) OPTO COUPLER (K5) OPTO COUPLER (L5)


OPTO COUPLER (M5) OPTO COUPLER (N5) OPTO COUPLER (O5)

OPTO COUPLER (P5)

Diagram 26 : Figures of opto-coupler wiring for SSRS.


2.1.4 PLC WIRING DIAGRAM

Diagram 27 : Figure of PLC wiring for SSRS.


LAGEND

A5 OPTOCOUPLER
B5 OPTOCOUPLER
C5 OPTOCOUPLER
D5 OPTOCOUPLER
E5 OPTOCOUPLER
F5 OPTOCOUPLER
G5 OPTOCOUPLER
H5 OPTOCOUPLER
I5 OPTOCOUPLER
J5 OPTOCOUPLER
K5 OPTOCOUPLER
L5 OPTOCOUPLER
M5 OPTOCOUPLER
N5 OPTOCOUPLER
O5 OPTOCOUPLER
P5 OPTOCOUPLER
K1 RELAY (FORWARD DC MOTOR)
K2 RELAY (REVERSE DC MOTOR)
K3 RELAY (FORWARD DC MOTOR)
K4 RELAY (REVERSE DC MOTOR)
H1 TOWER LAMP(GREEN)
H2 TOWER LAMP(YELLOW)
H3 TOWER LAMP(GREEN)

Table: Lagend for SSRS PLC wiring diagram.


Diagram 28 : Figure of PLC wiring for SSRS.

LAGEND

PB1 INITIAL CONDITION


PB2 STOP MOTOR
LS1 FORWARD DC MOTOR
LS2 REVERSE DC MOTOR
LS3 FORWARD DC MOTOR
LS4 REVERSE DC MOTOR

Table: Lagend for SSRS PLC wiring diagram.


2.1.5 POSITION MODULE WIRING DIAGRAM

Diagram 29 : Figure of position module wiring for SSRS.

LAGEND

CCW+ STEPPER DRIVER MOTOR


CW+ STEPPER DRIVER MOTOR
CCW- STEPPER DRIVER MOTOR
CW- STEPPER DRIVER MOTOR
S1 INDUCTIVE SENSOR
L 0V
M 0V

Table: Lagend for SSRS position module wiring diagram.


2.2 INSTRUMENT AND EQUIPMENT SPECIFICATION

The instrument and equipment for this machine divided into:


1. Mechanical
2. Electrical and Electronic

2.2.1 MECHANICAL COMPONENT

Component Description
Material : Aluminum
Block with flange Size : 200X280mm
Function : Positioning Table
Size : 40x40mm
Bearing Flange D= 27.4mm, d= 10.6mm
Function : Bearing Flange
Material : Mild Steel
Drawer Magazine
Function : To placed items in magazine
Material : Aluminum
Pusher Size : D= 12.7mm
Function : To dispense items from magazine
Material : Mild Steel
Gear (14 tooth) Size : 14 tooth
Function : Drive chain for positioning table
Material : Mild Steel
Size : 27 tooth
Gear (27 tooth) Function : Drive chain for positioning table
Material : Mild Steel
Chain Size : 324 (Industrial Standard)
Function : To move the positioning table
Table: Mechanical component specification.

2.2.2 ELECTRICAL AND ELECTRONIC COMPONENT


Component Description
Emergency Stop Input : 240 VAC
Push Button Output : 240 VAC
Input : 240 VAC
Selector Switch
Output : 240 VAC
Model : Siemens S7 200
PLC Input : 24 VDC
Output : 24 VDC
Model : Siemens EM 253
Position Module Input : 240 VAC
Output : 5 VDC
Power Window
Output : 12 VDC
Motor
Input Voltage : 240VAC
ELCB
Output Voltage : 240VAC
Model : ABB, Hager
Input Voltage : 240/415V
Input Voltage : 6A
Model : Hager
MCB Input Voltage : 240/415V
Input Voltage : 16A
Model : TAIAN JAYA
Input Voltage : 230/400V 50 HZ & 230/415V 50HZ
Input Voltage : 6C & 6A
Opto-coupler Type : 4N25
Type :100 ohm
Resistor
1000 ohm
Model : MYCOM
Stepper Motor Input : 24VDC

Inductive sensor Input :24VDC

Input : 12VDC
Limit switch
Model : MYCOM
Motor Driver Input : 24VDC
Output : 24VDC
Power Socket Type : 3 Pin

Table: Electrical and electronics component specification.

2.3 PROCESS PLAN


2.3.1 BLOCK DIAGRAM

PROTOCOL 2:
PROTOCOL 1:
USER VERIFICATION
INITIALIZING I/O CARD

PROTOCOL 4: PROTOCOL 3:
ITEM SELECTION USER MENU

PROTOCOL 5:
PROTOCOL 6:
CONFIRM ITEM
COLLECT ITEM

Diagram 30 : Figure of block diagram for SSRS process plan.

2.3.2 MACHINE PROCESS FLOWCHART


Start

User need to initialize


I/O Card

No
Initializing
ok?

Yes

Insert username and


password to login

Yes
Login User selection
ok? menu

No
1.0 2.0
Select View item
Item select
ok? history

1 Report of
dispense
End items
1

Stapler Writing Memo Fastener


Pad Pad

2
No No No No
Ok? Ok? Ok? Ok?

Refill Refill Refill Thumb


Yes
Red Yes Blue Yes Black Yes Tacks

Proceed Proceed Proceed Proceed


No No No
No
Ok? Ok? Ok? Ok?
3 3 3 3
Yes Yes Yes
Yes
Proceed Proceed Proceed
Proceed

3 3 3
3

End
2

Stapler Paper
A4 Paper bullet Clip Blue Pen

No No No No
Ok? Ok? Ok? Ok?

Black Marker Marker Marker


Yes Yes Yes Yes
Pen Red Blue Blue
Proceed Proceed Proceed Proceed
No No No
No
Ok? Ok? Ok? Ok?
3 3 3 3
Yes Yes Yes Yes
Proceed Proceed Proceed Proceed

3 3 3 3

End
2

Positioning table move


to the desire item

Pusher Extend

Pusher Retract

Positioning table
back to initial

End

Diagram 31 : Figure of machine process flowchart for SSRS process plan.


2.3.3 MACHINE SEQUENCES

In order to use the SSRS, users have to follow the sequence to dispense item.
Stated below is the sequence on how to operate the vending machine.

Protocol 1:
• User need to initialize I/O card as 1
• Then click enter for the next protocol

Protocol 2:
• User need to identify themselves to activate the system using user ID and
password
• Wait for the identification success for the next step to activate

Protocol 3:
• After identification successful, user needs to choose Select Items to select items or
Purchase History to view profile. (Select Profile is nothing to do with the sequence
to dispense items. It’s to view user profile only such as balance and total of items
that has been dispensing from user)
• Choose Select Items to continue the process

Protocol 4:
• New menu for items will pop-up
• Select the item that user wanted

Protocol 5:
• Clicks the item to confirm and proceed for the dispense item

Protocol 6:
• Collect item at the discharge section
2.4 START-UP, COMMISSIONING AND TEST

2.4.1 QUALITY CHECKING

First thing to do before use the recycled parts from previous or receives the items
from vendors, we need to have a quality checking to ensure the items are in good
condition and function well. The following table is the checking procedure for electrical
equipment.

ITEMS CHECKING PROCEDURES


MCB and ELCB • Check continuity using Multimeter.
• Check current rating to make sure it is able to
protect the system from overload current.
• Check resistance reading when switch is on,
ensure it is zero.
5V DC, 12V DC, • Apply 240V AC to Power Supply input,
24V DC Power • Read the output; make sure it is 5V DC, 12V DC
Supply and 24V DC
Emergency Stop • Ensure it has a NC contact.
Button • Check continuity using Multimeter.
PLC • Download a simple program to PLC
• Give 24V DC to all PLC inputs.
• Check the output voltage using Multimeter to
determine whether it sense the signal or not.
Inductive Sensor • Apply 24V DC to the sensor
• Check the output voltage using Multimeter.
Stepper Motor • Apply 24V DC to motor.
• Test runs the motor.
Motor driver • Apply 24V AC to motor driver
• Test runs the motor driver
Table: Quality checking for electrical component.

2.4.2 START-UP
For a convincing and proper start-up, please follow the instructions given
below to operate the machine.

1. Plug-in the power cord to a 415V AC/ 230V AC/ 240V AC supply
and turn the Selector Switch.
2. Switch ON the ELCB and all the MCBs.
3. Release the EMERGENCY STOP Buttons.
4. Turn ON the PC and monitor.
5. Key in user ID and password on the monitor to be allowed to use the
machine.
6. Double click on Stationery Storage And Retrieval System Icon at the
Start Menu.
7. Follow the instruction given in the system.

NOTE: This machine only run the MANUAL mode.

2.4.3 COMMISSIONING AND TEST


2.4.3.1 CHECK LIST FOR ELECTRICAL COMPONENTS

ITEMS FUNCTIONALITY
MCB and ELCB Good
5 VDC, 12 VDC, 24 VDC Power Supply Good
Emergency Stop Button Good
PLC Good
Inductive Sensor Good
Stepper Motor Good
Motor driver Good

Table: Checklist for electrical component functionality.

2.4.3.2 PROBLEM ENCOUNTERED AND COUNTERMEASURES

PROBLEM ENCOUNTERED COUNTERED MEASURES


• Items unable to dispense from magazine • Change the design and quantity
packaging of items
• The cancellation of belting and timing • Change the design from using pulley
pulley due to college policy and timing belt to chain and gear.
• Touch screen configuration class has been • We used PC monitor to replace touch
cancelled. We cannot configure our touch screen
screen to communicate with PC and PLC
• The stepper positioning is not fix to the • In the Ladder Diagram, we set the
place for pusher to stop due to the used of timer for done signal for each step
chain. The pusher have idle before the longer. So, the position of the pusher
operation can be seen before it pushes the item.
We can abort the operation if the
pusher is not in place.

Table: Problem encountered and countermeasure.

2.5 RESULT AND DISCUSSION

After finish the project implementation process, we must run the commissioning
and testing procedure to get the result of the project performance.

Due to the testing, it shows result that this machine able to run upon expectation.
The entire components function well and give an excellent result.

There were some problems occurs during the implementation process but we
manage to overcome the problems efficiently.

The result of commissioning:

1) The stepper positioning is not fix to the place for pusher to stop due to the
used of chain. The pusher have idle before the operation

2) Items unable to dispense from magazine because of the design and the quantity
of items in the packaging.
CHAPTER 3

PROJECT SUMMARY

3.1 SAFETY FEATURES

As a safety precaution, we have included all the safety equipments to provide the
safety features for our SSRS machine.

Items Safety Reason


1. Emergency Stop Button

Used to cut off the vending machine power supply


to stop all process when any accidents occur.

2. Circuit Breaker

Use Earth Leakage Circuit Breaker and Miniature


Circuit Breaker to cut off leakage current.

3. Control Panel Box Use as the container for the wiring and
connection. It can keep away from human reach.
4. Tower Lamp

Use to indicate the process that been running by


the machine.

5. Safety Precaution Notice

Use to let user used the machine appropriately


and safely.

Table: Safety items provided for SSRS.


3.2 INSTRUMENTS, EQUIPMENTS AND ENGINEERING COST

3.2.1 MECHANICAL COMPONENT

PURCHASED

NO. ITEMS QUANTITY PRICE PER TOTAL(RM)


UNIT(RM)
1. Aluminum Profile 40x40mmx5m 7pcs 47.00/m 1645.00
2. Gusset Element 40x40mm 50pcs 5.50 275.00
3. Hammer Head Screw M8x20 50pcs 3.00 300.00
4. Flange Nut M8 100pcs 0.30 30.00
5. Block with Flange 2pcs 350.00 700.00
6. Slotted Block 3pcs 49.00 147.00
7. End Cap 8pcs 2.50 20.00
8. Magnetic Lock 3pcs 16.70 50.10
9. Left Hinge 4pcs 6.40 25.60
10. Right Hinge 4pcs 6.40 25.60
11. Liromat Handle 3pcs 9.90 29.70
12. Mild Steel Container:
i) 403x57x17 1pcs 75.00 75.00
mm 1pcs 75.00 75.00
ii) 403x27x62 1pcs 75.00 75.00
mm 1pcs 85.00 85.00
iii) 403x92x27 1pcs 85.00 85.00
mm 1pcs 95.00 95.00
iv) 403x102x27 1pcs 95.00 95.00
mm 1pcs 95.00 95.00
v) 403x112x27 1pcs 95.00 95.00
mm 1pcs 100.00 100.00
vi) 403x122x47 1pcs 95.00 95.00
mm 1pcs 95.00 95.00
vii) 403x141x47 1pcs 95.00 95.00
mm 1pcs 105.00 105.00
viii) 403x141x47 1pcs 105.00 105.00
mm 1pcs 110.00 110.00
ix) 403x141x47 1pcs 75.00 75.00
mm 1pcs 145.00 145.00
x) 403x152x52 1pcs 145.00 145.00
mm 1pcs 145.00 145.00
xi) 403x154x42
mm
xii) 403x154x42
mm
xiii) 403x154x42
mm
xiv) 403x172x32
mm
xv) 403x172x32
mm
xvi) 403x204x27
mm
xvii) 603x92x32
mm
xviii) 403x306x22
6mm
xix) 403x306x22
6mm
xx) 403x306x22
6mm
13. Acrylic Sheet:
i) 3x1000x1700mm 4pcs 170.00 680.00
ii) 3x1000x1000mm 2pcs 128.00 256.00

NO. ITEMS QUANTITY PRICE PER TOTAL(RM)


UNIT(RM)
14. Aluminum Plate:
i) 1x1220x350mm 1pcs 32.00 32.00
ii) 8x250x320mm 1pcs 77.00 77.00
iii) 1x60x1220mm 2pcs 6.50 13.00
iv) 10x20x880mm 1pcs 24.00 24.00
v) D=12.7x300mm 2pcs 4.50 9.00
15. Angle Iron (L) 30x30x3x600mm 18pcs 8.00 144.00
16. U Beam 30x1000x1700mm 5pcs 13.00 65.00

TOTAL (RM) 6538.00

Table: Purchased mechanical component.


RECYCLED

NO. ITEMS QUANTITY PRICE PER TOTAL(RM)


UNIT(RM)
1. Aluminum Profile 40x40mmx5m 3pcs 47.00/m 141.00
2. Gusset Element 40x40mm 30pcs 5.50 165.00
3. Gusset Element 20x28mm 30pcs 4.50 135.00
4. Gusset Element 20x20mm 4pcs 7.20 28.80
5. Hammer Head Screw M8x20 30pcs 3.00 90.00
6. Flange Nut M8 30pcs 0.30 9.00
7. Liromat Handle 3pcs 9.90 29.70
8. Right Hinge 2pcs 6.40 12.80
9. Left Hinge 2pcs 6.40 12.80
10. Caster Wheel 4pcs 8.00 32.00
11. Black Strip (L=2m) 5pcs 5.20 26.00

TOTAL (RM) 682.10

Table: Recycled mechanical component.

MISCELLANEOUS

NO. ITEMS QUANTITY PRICE PER TOTAL(RM)


UNIT(RM)
1. Chain Detach 1pcs 20.00 20.00
2. Screw and Nut 100pcs 0.15 15.00
3. Sand paper 2pcs 2.00 2.00
4. Drill Bit (3.3mm) 1pcs 1.00 1.00
5. Grinder 1pcs 3.00 3.00
6. Sand Paper 3pcs 0.66 2.00
7. Screw and Nut 30pcs 0.25 7.50
8. Grinder 2pcs 2.65 5.30
9. Door Lock 2pcs 0.80 1.60
10. Spray Grey 6pcs 6.00 36.00
11. RS 35 Cable Link 8pcs 3.20 25.60
12. TOYO Grease 1pcs 8.50 8.50
13. Mild Steel Plate:
i) 4.5x40x40mm 16pcs 1.50 24.00
ii) 6x104x114mm 1pcs 4.00 4.00
iii) 6x100x96mm 2pcs 3.00 6.00
iv) 6x44x34mm 6pcs 1.50 9.00
v) 4.5x844x44mm 4pcs 10.00 40.00
vi) 4.5x44x1024mm 2pcs 12.00 24.00
vii) 4.5x44x1004mm 4pcs 11.90 47.60
14. Shaft:
i) 10x500mm 1pcs 2.00 2.00
ii) 10x150mm 1pcs 0.60 0.60
iii) 10x260mm 4pcs 1.00 4.00
iv) 10x60mm 2pcs 0.30 0.60
15. Aluminum Plate
(0.7mmx4inchx8inch) 1pcs 100.00 100.00
16. ISC Fabrication (Slotted Block) 6pcs 15.00 90.00
17. Welding mechanical part - - 100.00
18. RS35 QCM Roller Chain 10FT 4.00/FT 40.00
19. Gear (14 tooth) 16pcs 8.00 128.00
20. Gear (27 tooth) 1pcs 14 14.00
21. 628 ZZ ZYZ Bearing 26pcs 3.00 78.00
22. 6000 ZZ KDYD Bearing 16pcs 3.00 48.00
23. RS35 CONN LINK 5pcs 2.50 12.50
24. RS35 Roller Chain 10FT 3.50/FT 35.00
25. SOC Sec Screw M4x16 Cup 30pcs 0.10 3.00
26. Flat HD SOC Screw M8x35 35pcs 0.26 9.10
27. Hex Nut M8 Black 55pcs 0.038 2.10
28. MS Flat Washer M8 105pcs 0.028 3.00
29. MS Flat Washer M5 50pcs 0.01 0.50

NO. ITEMS QUANTITY PRICE PER TOTAL(RM)


UNIT(RM)
30. SOC HD Cap Screw M6x16 30pcs 0.073 2.20
31. Hex Nut M6 Black 80pcs 0.025 2.00
32. MS Flat Washer M6 20pcs 0.025 0.50
33. SOC HD Cap Screw M6x20 30pcs 0.08 2.40
34. SOC HD Cap Screw M8x20 30pcs 0.15 4.50
35. Flat HD SOC Screw M8x16 10pcs 0.16 1.60
36. Hex Nut M8 20pcs 0.05 1.00
37. MS Flat Washer M12 20pcs 0.06 1.20

TOTAL (RM) 967.90

Table: Miscellaneous mechanical component.


3.2.2 ELECTRICAL COMPONENTS

PURCHASED

NO. ITEMS QUANTITY PRICE PER TOTAL(RM)


UNIT(RM)
1. Cable Tie 4” 100pcs 1 pack 6.00 6.00
2. Selector Switch ON/OFF 1pcs 23.00 23.00
3. Emergency Push Button NC 1pcs 24.80 24.80
4. PVC Trunking Grey (L=3m) 1pcs 10.50 10.50
5. DC motor 12V 1pcs 55.00 55.00
6. Tower Lamp 240 VAC 3 Indicator 1pcs 120.00 120.00
7. Cable Tie Marker 1 pack 39.00 39.00
8. Power Supply 12V, 24 VDC,
4.5A 2pcs 150 300.00
9. OMRON Relay-MY2 DC 24 or
12V 5pcs 38.00 190.00
10. Limit Switch OMRON 4 4.50 18.00

TOTAL (RM) 786.30

Table: Purchased electrical component.

RECYCLED

NO. ITEMS QUANTITY PRICE PER TOTAL(RM)


UNIT(RM)
1. DC motor 12V 1pcs 55.00 55.00
2. Stepper Motor 1pcs 2650.00 2650.00
3. Motor Driver 1pcs 1260.00 1260.00
4. PC I/O card c/w Terminal Block 1pcs 1600.00 1600.00
5. Inductive sensor 1pcs 150.00 150.00
6. Terminal Block 35pcs 0.90 31.50
7. MCB 2pcs 3.80 7.60
8. ELCB 1pcs 48.00 48.00

TOTAL (RM) 5802.10

Table: Recycled electrical component.

MISCELLANEOUS

NO. ITEMS QUANTITY PRICE PER TOTAL(RM)


UNIT(RM)
1. 2 Pin Multi Plug 1pcs 4.80 4.80
2. 4N25 2pcs 2.00 4.00
3. CON 5A Connector 8pcs 1.40 11.20
4. PCB Board 2pcs 5.50 11.00
5. Cable Lug (100pcs) 2pkt 0.10 20.00
6. SD 10/C-Green Switch 1pcs 3.00 3.00
7. SD 10/C-Red Switch 1pcs 3.00 3.00
8. MYRO Switch 4pcs 4.00 16.00
9. 4N25 I/C Stand 16pcs 1.50 24.00
10. PCB Board 1pcs 1.80 1.80
11. LED 24 VDC S722C 16pcs 2.50 40.00
12. Magnetic Switch 5pcs 5.00 25.00
13. IC Opto Coupler 4N25 16pcs 0.30 4.80
14. RS35X14TXIR 13pcs 8.00 114.00
15. RS35X27XIR 1pcs 17.00 17.00
16. Terminal Block 95pcs 0.90 85.50
17. Din Rail 2m 5.50/m 11.00
18. PIN 1.25 AF 100pcs 0.13 13.00
19. SN 30 Stand 12pcs 0.90 10.80
20. Wiring Duct 2m 9.00/m 18.00
21. Cable Lug Pin (100pcs) 2pkt 12.00/pkt 24.00
22. 3 Pin Socket 1pcs 3.00 3.00
23. MDO Wiring Duct 1m 8.00/m 8.00
24. ZPS 6A SP MCB 2pcs 3.80 7.60

TOTAL (RM) 480.50

Table: Miscellaneous electrical component.

3.2.3 TOTAL COSTING

For the total costing, we have concluded with the purchase, recycled and
miscellaneous components. As shown below is the total cost for the Mechanical and
Electrical components.

MECHANICAL:
Purchase: RM 6538.00
Recycled: RM 682.10
Miscellaneous: RM 967.90
TOTAL: RM 8188.00

ELECTRICAL:
Purchase: RM 786.30
Recycled: RM 5802.10
Miscellaneous: RM 480.50
TOTAL: RM 7068.90

Total Project Cost = Mechanical Components + Electrical Components

Total Project Cost = RM 8188.00 + RM 7068.90


= RM 15,256.90

3.3 CONCLUSION

We can conclude this project does have a lot to offer in terms of the design, cost,
and ability. Besides that, it generates opportunities for the student to develop practical
ability besides gaining a lot of knowledge and information concerning in technical.

This project emphasizes teamwork spirit among students besides being punctual in
completing the task in the given period of time. Therefore, punctuality and teamwork
among the students can be inculcated. It also develops a good relationship among the
group members.
Beside that, we can save a lot of time and money. By completing all the
implementation of the project, each member of the group will get benefit and deserve
some credit as pointed below:-

i. Able to design a machine that can organize the stationary merchandise.


ii. Able to develop a system that fully controlled by computer base.
iii. Able to develop an efficient office management by equip the latest technology
for monitoring system.
iv. Able to improve inventory system and simulate the industrial practices on
realistic industrial system model.

The project introduces a new alternative in industrial automation. In the future,


people can adopt the knowledge and refer to the concept especially in STATIONARY
STORAGE AND RETRIEVAL SYSTEM. It is also gives a foresight view in application of
PLC, Mechanical Electrical and Computer programming. Lastly, we are pleased that our
project can be implemented successfully.

3.4 RECOMMENDATION

Due to this prototyping project, we have overlooked to improvise this project in the
future. Stated below is the recommendation and improvisation to this project:

1) The positioning chain, it can be replaced with belting


2) The used of gear can be replaced by the usage of timing pulley
3) The usage of PC to store and retrieve the database can be improvise by
replacing it with industrial touch panel
4) The material of the magazine can be substitute with acrylic, so it is lighter.
Proposed Gantt Chart
Reviewed Gantt Chart
Project Progress Report
Vendor data
Appendix 5: Layout view for all parts of SSRS.

5.1 Base of SSRS.


5.2 Silo and discharge section of SSRS.
5.3 Movable drawer for upper container of SSRS.
5.4 Movable drawer for bottom container of SSRS.
5.5 Upper and lower Pusher section of SSRS.
5.6 Stepper section of SSRS.
5.7 Positioning table of SSRS.
5.8 Bearing flange of SSRS.
5.9 Magazine for A4 and writing paper of SSRS.
5.10 Magazine for red, blue and black marker of SSRS.
5.11 Magazine for blue and black marker of SSRS.
5.12 Magazine for stapler bullet of SSRS.
5.13 Magazine for paper clips of SSRS.
5.14 Magazine for stapler of SSRS.
5.15 Magazine for thumb tack of SSRS.
5.16 Magazine for red, blue and black ink refill of SSRS.
5.17 Magazine for fastener of SSRS.
5.18 Magazine for memo pad of SSRS.
Position 1 : Stapler

Initial Condition

I 1.4

NS Stepper Motor Enable


Step 1
M 0.0

I 1.4

Step 2 NS Positioning Table Rotate

M 0.2

T 37 I 2.5

NS Pusher 1 Extend
Step 3
M 11.0

I 2.6

Step 4 NS Pusher 1 Retract

M 11.1

Q 0.0 I 2.5

Step 5 NS Positioning Table Seek Initial Position

M 10.0
Position 2 : Paper Fastener

Initial Condition

I 0.2

NS Stepper Motor Enable


Step 1
M 0.0

I0.2

Step 2 NS Positioning Table Rotate

M 0.3

T 38 I 2.5

NS Pusher 1 Extend
Step 3
M 11.0

I 2.6

Step 4 NS Pusher 1 Retract

M 11.1

Q 0.0 I 2.5

Step 5 NS Positioning Table Seek Initial Position

M 10.0
Position 3 : Writing Pad

Initial Condition

I 1.5

NS Stepper Motor Enable


Step 1
M 0.0

I 1.5

Step 2 NS Positioning Table Rotate

M 0.4

T 39 I 2.5

NS Pusher 1 Extend
Step 3
M 11.0

I 2.6

Step 4 NS Pusher 1 Retract

M 11.1

Q 0.0 I 2.5

Step 5 NS Positioning Table Seek Initial Position

M 10.0
Position 4 : Memo Pad

Initial Condition

I 1.6

NS Stepper Motor Enable


Step 1
M 0.0

I 1.6

Step 2 NS Positioning Table Rotate

M 0.5

T 40 I 2.5

NS Pusher 1 Extend
Step 3
M 11.0

I 2.6

Step 4 NS Pusher 1 Retract

M 11.1

Q 0.0 I 2.5

Step 5 NS Positioning Table Seek Initial Position

M 10.0
Position 5 : Thumb Tacks

Initial Condition

I 1.7

NS Stepper Motor Enable


Step 1
M 0.0

I 1.7

Step 2 NS Positioning Table Rotate

M 0.6

T 41 I 2.5

NS Pusher 1 Extend
Step 3
M 11.0

I 2.6

Step 4 NS Pusher 1 Retract

M 11.1

Q 0.0 I 2.5

Step 5 NS Positioning Table Seek Initial Position

M 10.0
Position 6 : Marker Ink Refill - Red

Initial Condition

I 1.0

NS Stepper Motor Enable


Step 1
M 0.0

I 1.0

Step 2 NS Positioning Table Rotate

M 0.7

T 42 I 2.3

NS Pusher 2 Extend
Step 3
M 11.2

I 2.4

Step 4 NS Pusher 2 Retract

M 11.3

Q 0.3 I 2.3

Step 5 NS Positioning Table Seek Initial Position

M 10.1
Position 7 : Marker Ink Refill - Blue

Initial Condition

I 1.1

NS Stepper Motor Enable


Step 1
M 0.0

I 1.1

Step 2 NS Positioning Table Rotate

M 1.0

T 43 I 2.3

NS Pusher 2 Extend
Step 3
M 11.2

I 2.4

Step 4 NS Pusher 2 Retract

M 11.3

Q 0.3 I 2.3

Step 5 NS Positioning Table Seek Initial Position

M 10.1
Position 8 : Marker Ink Refill - Black

Initial Condition

I 0.0

NS Stepper Motor Enable


Step 1
M 0.0

I 0.0

Step 2 NS Positioning Table Rotate

M 1.1

T 44 I 2.3

NS Pusher 2 Extend
Step 3
M 11.2

I 2.4

Step 4 NS Pusher 2 Retract

M 11.3

Q 0.3 I 2.3

Step 5 NS Positioning Table Seek Initial Position

M 10.1
Position 9 : Bullet For Stapler

Initial Condition

I 0.4

NS Stepper Motor Enable


Step 1
M 0.0

I 0.4

Step 2 NS Positioning Table Rotate

M 1.2

T 45 I 2.3

NS Pusher 2 Extend
Step 3
M 11.2

I 2.4

Step 4 NS Pusher 2 Retract

M 11.3

Q 0.3 I 2.3

Step 5 NS Positioning Table Seek Initial Position

M 10.1
Position 10 : Paper Clips

Initial Condition

I 0.5

NS Stepper Motor Enable


Step 1
M 0.0

I 0.5

Step 2 NS Positioning Table Rotate

M 1.3

T 46 I 2.3

NS Pusher 2 Extend
Step 3
M 11.2

I 2.4

Step 4 NS Pusher 2 Retract

M 11.3

Q 0.3 I 2.3

Step 5 NS Positioning Table Seek Initial Position

M 10.1
Position 11 : Ball Pen - Blue

Initial Condition

I 0.6

NS Stepper Motor Enable


Step 1
M 0.0

I 0.6

Step 2 NS Positioning Table Rotate

M 1.4

T 47 I 2.3

NS Pusher 2 Extend
Step 3
M 11.2

I 2.4

Step 4 NS Pusher 2 Retract

M 11.3

Q 0.3 I 2.3

Step 5 NS Positioning Table Seek Initial Position

M 10.1
Position 12 : Ball Pen - Black

Initial Condition

I 0.7

NS Stepper Motor Enable


Step 1
M 0.0

I 0.7

Step 2 NS Positioning Table Rotate

M 1.5

T 48 I 2.3

NS Pusher 2 Extend
Step 3
M 11.2

I 2.4

Step 4 NS Pusher 2 Retract

M 11.3

Q 0.3 I 2.3

Step 5 NS Positioning Table Seek Initial Position

M 10.1
Position 13 : A4 Paper

Initial Condition

I 1.2

NS Stepper Motor Enable


Step 1
M 0.0

I 1.2

Step 2 NS Positioning Table Rotate

M 1.6

T 49 I 2.3

NS Pusher 2 Extend
Step 3
M 11.2

I 2.4

Step 4 NS Pusher 2 Retract

M 11.3

Q 0.3 I 2.3

Step 5 NS Positioning Table Seek Initial Position

M 10.1
Position 14 : Marker Pen - Red

Initial Condition

I 1.3

NS Stepper Motor Enable


Step 1
M 0.0

I 1.3

Step 2 NS Positioning Table Rotate

M 1.7

T 50 I 2.3

NS Pusher 2 Extend
Step 3
M 11.2

I 2.4

Step 4 NS Pusher 2 Retract

M 11.3

Q 0.3 I 2.3

Step 5 NS Positioning Table Seek Initial Position

M 10.1
Position 15 : Marker Pen - Blue

Initial Condition

I 0.1

NS Stepper Motor Enable


Step 1
M 0.0

I 0.1

Step 2 NS Positioning Table Rotate

M 2.0

T 51 I 2.3

NS Pusher 2 Extend
Step 3
M 11.2

I 2.4

Step 4 NS Pusher 2 Retract

M 11.3

Q 0.3 I 2.3

Step 5 NS Positioning Table Seek Initial Position

M 10.1
Position 16 : Marker Pen - Black

Initial Condition

I 0.3

NS Stepper Motor Enable


Step 1
M 0.0

I 0.3

Step 2 NS Positioning Table Rotate

M 2.1

T 52 I 2.3

NS Pusher 2 Extend
Step 3
M 11.2

I 2.4

Step 4 NS Pusher 2 Retract

M 11.3

Q 0.3 I 2.3

Step 5 NS Positioning Table Seek Initial Position

M 10.1

Вам также может понравиться