(PLC Automation of Cartoning Machine IC

150)

2. Introduction
AProgrammable controller is a solid state user programmable control system with
functions to control logic, sequencing, timing, arithmetic data manipulation and counting
capabilities. It can be viewed as an industrial computer that has a central processor unit,
memory, input output interface and a programming device. The central processing unit
provides the intelligence of the controller. It accepts data, status information from various
sensing devices like limit switches, proximity switches, executes the user control program
store in the memory and gives appropriate output commands to devices like solenoid valves,
switches etc.
Input output interface is the communication link between field devices and the controllers;
field devices are wired to the I/O interfaces. Through these interfaces the processor can
sense and measure physical quantities regarding a machine or process, such as, proximity,
position, motion, level etc. Based on status sensed, the PLC issues command to output
devices such as valves, motors, alarms, etc.
Programmer unit provides the man machine interface. It is used to enter the application
program, which often uses a simple user-friendly logic.
BENEFITS OF PROGRAMMABLE CONTROLLERS
Programmable controllers are made of solid state components and hence provide high
reliability.
They are flexible and changes in sequence of operation can easily be incorporated due to
programmability. They may be modular in nature and thus expandability and easy
installation is possible.
Use of PLC results in appreciable savings in Hardware and wiring cost.
They are compact and occupy less space.
Eliminate hardware items like Timers, counters and Auxiliary relays. The presence for
timers and counters has easy accessibility.
PLC can control a variety of devices and eliminates the need for customized controls.
Easy diagnostic facilities are provided as a part of the system. Diagnosis of the external
systems also becomes very simple. Thus easy service/maintenance.
Programming devices provide operator friendly interface with the machine. Being an
outcome of the latest art of electronics technology, Programmable controllers provide higher
level of performance with computers is possible. Useful management data can be obtained
and maintained.

1
 (PLC Automation of Cartoning Machine IC
150)

It has total protections against obsolescence and has wide scope for upgrade

Cartoning Machine IC 150

GENERAL
The IC 150 is fully automatic intermittent horizontal cartoners that automatically
open/fold cartons, infeed products, insert leaflet into the cartons, coding and then
automatically close the carton. The IC 150 can be fitted with a wide range of feeding units
which automatically separate and orientate the product before it is carefully introduced into
the previously opened and erected carton. The PLC automatically controls and manages all
packaging steps with any malfunction being indicated on the display, stopping the machine if
necessary so in order for any remedial action to be taken

2
 (PLC Automation of Cartoning Machine IC
150)

Machine Layout

3
 (PLC Automation of Cartoning Machine IC
150)

4
 (PLC Automation of Cartoning Machine IC
150)

3. Process Description
3.1 Product Infeed
Blister Dispensing
Blister Magazine: Here blister arrives in blister magazine through adjustable extension
conveyor of Blister forming machine. The extension conveyor mounted on blister magazine
& it is fixed with knob. Blister magazine is equipped with two capacitive sensor ‘Blister
minimum load sensor’ & ‘Blister maximum load sensor’
Keyence PLC: A Keyence KV 10T PLC used here which controls various operation of
Blister dispensing .It works on 24V dc supply. Input to Keyence PLC is given by main PLC
through alleged connector. Blister dispensing works due to proper synchronization of
Keyence PLC & main PLC. Keyence PLC has four outputs two of which are further
connected to four EM coils & remaining two are connected to sensors.
Electromagnetic Coils: Four EM coils holds blister inside blister magazine when it gets
energized it allow dropping blister inside each pocket of bucket conveyor. At time only one
blister is dropped. Number of blister fall inside each packet is decided by settings made on
control panel.

Bucket Conveyor
This bucket conveyor is just below the blister magazine having fixed number of bucket
whose sizes can be changed as per pack size. While moving along the blister conveyor
‘Product check sensor’ check weather exact number of blisters fell inside each bucket or not

3.2Carton Feeding
The machine is equipped with carton magazine where the carton is picked up on conveyor.
The carton magazine is equipped with a carton minimum load photocell called as ‘Minimum
carton load sensor’
Carton is moved by conveyor to the line parallel to pocket conveyor called carton line. While
being moved by carton chain rack carton is formed & prepared to receive the product.
Other photocells are fixed in the magazine they check for proper carton pick up.

3.3Carton Forming
Carton is formed while being moved along the line parallel to pocket chain.
Carton forming process is pneumatically operated. Two suction paths pick up & set the two
carton sides apart further mechanical components fold the side flaps

5
 (PLC Automation of Cartoning Machine IC
150)

The chain transport & forming conveyor are equipped with two photocells ‘Upper forming
check’ & ‘Lowe forming check’
Carton above the conveyor is guided at the top by mobile guide here an inductive sensor
called as ‘Carton guide up sensor’ is attached for this.

3.4Product Insertion
Products are inserted into the carton by pusher.
Pusher is equipped with safety device which move back the pushers guide in case the
product is harmed to be inserted.
Safety system is controlled by the sensor’ Pusher Safety Sensor’ that avoid further damages
to the machine. If blisters are not placed properly or they are not present inside pocket or
bucket pusher comes in contact
Leaflet is also inserted along with blisters inside the carton by the pusher. Mobile plate plays
important role in this process. Mobile plate catches the leaflet meanwhile pusher pushes the
fixed number of blisters inside mobile plate in such away that leaflet holding all blisters
moves inside carton.

6
 (PLC Automation of Cartoning Machine IC
150)

3.5 Side Flap Closing & Numbering

For proper side flap closing each carton (whether properly formed or not) are mounted on
carton carrying conveyor guide before that every carton has to through central numbering
device. Flaps are closed by simultaneous movement of central comb located in between two
side comb. While carton moved along conveyor carton code is read by carton code reader
then with the help of flap closure flap A , A’& B,B’ are closed further lower flap numbering
& upper flap numbering is performed.
Knives placed along side of central gripper comb folds the flap C, C’ & tuck in closer
perform final closing.
At the end rejected cartons are diverted to different direction & properly formed cartons are
come out through outlet.

7
 (PLC Automation of Cartoning Machine IC
150)

OPERATION SEQUENCE

4. Proximity Sensors Used in Machine Tools

A proximity sensor is a sensor able to detect the presence of nearby objects without any
physical contact. A proximity sensor often emits an electromagnetic or electrostatic field, or
a beam of electromagnetic radiation (infrared, for instance), and looks for changes in the
field or return signal. The object being sensed is often referred to as the proximity sensor's
target. Different proximity sensor targets demand different sensors. For example, a capacitive

8
 (PLC Automation of Cartoning Machine IC
150)

or photoelectric sensor might be suitable for a plastic target; an inductive proximity sensor
requires a metal target.
The maximum distance that this sensor can detect is defined "nominal range". Some sensors
have adjustments of the nominal range or means to report a graduated detection distance.

4.1 CAPACITIVE SENSOR

4.1.1Principle
Capacitive dimensional measurement requires three basic components:
• A probe that uses changes in capacitance to sense Changes in distance to the target,
• Driver electronics to convert these changes in capacitance into voltage changes,
• A device to indicate and/or record the resulting voltage change.

A continuous 50-kHz excitation square wave applied to the source (SRC) side of the sensor,
to set up the electric field in the capacitive sensor. The stimulus creates an electric field in the
sensor that partially protrudes through the overlay plastic. The capacitance-input side is
connected to the input of the capacitance-to-digital converter
4.1.2 Blister minimum/ maximum load sensor
Blister magazine is equipped with two capacitive sensor called as ‘Blister minimum load
sensor’ & ‘Blister maximum load sensor’. Blister minimum load sensor gets off if no. of
blister in magazine goes below minimum level & blister maximum load sensor takes care of
that number of blister should not go beyond predetermined limit

4.2 INDUCTIVE SENSOR

Inductive proximity sensors are noncontact proximity devices that set up a radio frequency
field with an oscillator and a coil. The presence of an object alters this field and the sensor is
able to detect this alteration. An inductive proximity sensor comprises an LC oscillating

9
 (PLC Automation of Cartoning Machine IC
150)

circuit, a signal evaluator, and a switching amplifier. The coil of this oscillating circuit
generates a high-frequency electromagnetic alternating field. This field is emitted at the
sensing face of the sensor. If a metallic object (switching trigger) nears the sensing face,
eddy currents are generated. The resultant losses draw energy from the oscillating circuit and
reduce the oscillations. The signal evaluator behind the LC oscillating circuit converts this
information into a clear signal. The measurement of proximity, position and displacement of
objects is essential in many different applications: valve position, level detection, process
control, machine control, security, etc.

Important specifications for proximity sensors, inductive include operating distance,

repeatability, field adjustable, and minimum target distance. Rated operating distance is the
distance at which switching takes place. Repeatability is the distance within which the
sensor repeat ably switches. It is a measure of precision. Field adjustable sensors can be
adjustable while in use. Depending on the sensor's technology, there can be minimum target
size requirements.

10
 (PLC Automation of Cartoning Machine IC
150)

Load configurations are also important parameters to consider. Inductive proximity sensors
may switch an AC load or a DC load. DC load configurations can be NPN or PNP. NPN is a
transistor output that switches the common or negative voltage to the load; load connected
between sensor output and positive voltage supply. PNP is a transistor output that switches
the positive voltage to the load; load connected between sensor output and voltage supply
common or negative. Wire configurations are 2-wire, 3-wire NPN, 3-wire PNP, 4-wire NPN,
and 4-wire PNP. Switch types can be normally open (NO) or normally closed (NC). Switch
specifications include whether or not the switch is normally open or normally closed. Switch
repeatability and maximum switching frequency are important parameters to consider. The
switch may be a NAMUR type switch, a specialized switch for switching a resistive load.
Requires an external amplifier.

11
 (PLC Automation of Cartoning Machine IC
150)

4.2.1 Pusher Safety Sensor

Pusher is equipped with safety device which move back the pushers guide in case the
product is harmed to be inserted.
Safety system is controlled by the sensor ’Pusher Safety Sensor’ that avoid damages to
pusher. If blisters are not placed properly in bucket of pocket conveyor or they are not
present inside pocket or bucket, pusher comes in contact in that case pusher moves
backward. In this case alarm condition is occurred & machine stops
4.2.2 Product check sensor
While moving along the blister conveyor ‘Product check sensor1’ check weather exact
number of blisters are present inside each bucket or not whereas ‘Product check sensor2’
senses extra blister in pocket of blister conveyor. If such condition occurs blisters are
rejected form blister rejection outlet here machine does not stop
4.2.3 Carton magazine right/left safety sensor
They are the carton guide up sensors. It ensures proper alignment of the cartons.
4.2.4Clutch machine safety sensor
The operation of this sensor is mainly in two stages:
1). ON: When this sensor is ON, then the main motor works properly.

12
 (PLC Automation of Cartoning Machine IC
150)

2). OFF: When this sensor is OFF, then either the main motor is not working properly or a
load fault had occurred in the working of the motor. Hence this clutch moves outwards.
4.2.5 Hand wheel sensor
This senor is mainly used for manual machine check. This sensor mainly operates in two
modes:
ON: When this sensor is ON, the machine works automatically.
OFF: When this sensor is OFF, the machine is working in manual mode.

4.3 FIBER OPTIC SENSOR

4.3.1 Principle
A fiber optic sensor is a sensor that uses optical fiber either as the sensing element ("intrinsic
sensors"), or as a means of relaying signals from a remote sensor to the electronics that
process the signals ("extrinsic sensors"). Fibers have many uses in remote sensing.
Depending on the application, fiber may be used because of its small size, or the fact that no
electrical power is needed at the remote location, or because many sensors can be
multiplexed along the length of a fiber by using different wavelengths of light for each
sensor, or by sensing the time delay as light passes along the fiber through each sensor. Time
delay can be determined using a device such as an optical time-domain reflectometer.

4.3.1 Leaflet Check Sensor

It checks that leaflet magazine has properly released the leaflet & gripper has picked it up if
it is not pusher does not push blister into carton & at finally carton is rejected
4.3.2 Carton upper/lower forming check
It is mainly used to check the carton is properly formed or not i.e. it is fully opened or not &
is ready to accept blisters along with leaflet

4.5 PHOTOELECTRIC SENSOR

Photoelectric Sensors detect objects, changes in surface conditions, and other items through a
variety of optical properties.
A Photoelectric Sensor consists primarily of an Emitter for emitting light and a Receiver for
13
 (PLC Automation of Cartoning Machine IC
150)

receiving light. When emitted light is interrupted or reflected by the sensing object, it
changes the amount of light that arrives at the Receiver. The Receiver detects this change and
converts it to an electrical output. The light source for the majority of Photoelectric Sensors
is infrared or visible light (generally red, or green/blue for identifying colors). These Fibers
Units can be used in a variety of applications, such as detecting the presence of work pieces
and positioning

4.5.1 Minimum carton load sensor

The carton magazine is equipped with a carton minimum load photocell called as ‘Minimum
carton load sensor’ checks for presence of carton inside magazine. It gets off if number of
cartons goes below minimum level or magazine is empty.
4.5.2Minimum leaflet load sensor
The leaflet magazine is equipped with a ‘Minimum leaflet load sensor’ checks for presence
of leaflet inside magazine. It gets off if number of leaflet goes below minimum level or
magazine is empty.

14
 (PLC Automation of Cartoning Machine IC
150)

5. Control Elements
5.1 Solenoid valve
5.1.1 Pusher Forward.
This sensor when activated is mainly used to push the blister along with the leaflet into the
carton with the help of a pusher. However when it is deactivated, the pusher returns to its
original position.

5.1.2 Carton Rejection.

These two sensors are mainly used to reject the carton in any case of deformity in the carton
or the blister or the leaflet.

5.1.3 Pusher Backward.

15
 (PLC Automation of Cartoning Machine IC
150)

This sensor is mainly used to push the pusher backward after the blister along with the leaflet
enters the carton.

5.1.4 Leaflet Suction.

This is used to pick up a single leaflet from the leaflet magazine and push it along with the
blister into the carton.

5.1.5 Carton Suction.

This is used to pull up the carton from the carton magazine into which the blister and leaflet
enters.

5.1.6 Carton Forming.

This sensor is mainly used to form the carton by suction method.

6. ENCODER FUNCTION
Encoder is electronic device, which is responsible to step-by-step execution (on degree basis)
of entire process of IC 150.
7. INDUCTION MOTOR & DRIVE
7.1 MOTOR:
Induction motor works on the principle of magnetic effect of electric Current. There is a shaft
made up of soft iron core, which is attached to electric supply via iron brushes. The shaft is
attached surrounded by strong electro magnets. When we apply current to motor assembly
due to interaction of two electromagnets torque forces gets developed, perpendicular to shaft
of motor, this makes motor shaft to start rotating. Mechanical assembly attaches the motor
shaft to machine drive.
7.2 MOTOR DRIVE:

16
 (PLC Automation of Cartoning Machine IC
150)

In IC 150 single motor is used to drive entire machine. This is used to get perfect
synchronization of entire unit of IC 150.Drive is a complex mechanical part of machine,
which is responsible for distribution of mechanical power to the various parts of IC 150.
Drive takes input power from motor & with the help of gears & chain assembly it distributes
the power to other devices as output.
The various parts which are connected to drive assembly as follows:
1> Tucker assembly.
2> Carton conveyor.
3> Blister conveyor.
4> Leaflet assembly.

17
 (PLC Automation of Cartoning Machine IC
150)

18