DEBRE MARKOS UNIVERSITY

COLLEGE OF TECHNOLOGY
DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING
Design and Simulation of Automatic Sorting and Stacking System in manufacturing
industry
Semester project report submitted in partial fulfillment of the requirement for the
award of the degree of Bachelor of Science in electrical engineering
POWER STREAM
By
GROUP MUMBER.................... .......................... ID
1, ADANE TAZIE.............................................TER/2644/04
2, GEBREMEDIN MASRESHA........................TER/3308/04
3, FENTAHUN JENBERIE................................TER/2442/04
4, ASMAMAW MASCHALU.............................TER/2378/04
5, MENGISTU GIZACHEW..............................TER/1975/0

Adviser: Gebrehiwot M.
Summited day June 8 2015

Certificate/Declaration
This is to certify that the project report entitled [Design and Simulation of Automatic
Sorting and Stacking System in the Manufacturing Industry] being submitted by

GROUP MUMBER....................................................ID
1, ADANE TAZIE.............................................TER/2644/04
2, GEBREMEDIN MASRESHA........................TER/3308/04
3, FENTAHUN JENBERIE................................TER/2442/04
4, ASMAMAW MASCHALU.............................TER/2378/04
5, MENGISTU GIZACHEW...............................TER/1975/04

Guide Name

Signature

Head of the Department

Advisor

ACKNOWLEDGEMENT

Firstly, we would like to thank GOD. Because has helped our to complete this semester
Project report .We would lack words, how to express my respect for our father who used
to inspire our from our Childhood by giving his precious advice to get our learned. It is my
pleasure to
Acknowledge the rest of our family also. We would like to thank our advisor, Gebrehiwot
Miruts , for his guidance throughout the course of this project. He helped us immensely
with both the technical and administrative aspects of our work. We would like to apologize
our teacher, Dr. Ruvel Cuasito to help general introduced about the software (automation
studio software) and how to organizing the component of each software component such as
input output component control circuit and power circuit .
We would like to apologize to any person or people that have been involved if there are any
mistakes that I have done in the duration of this semester project.

ABSTRACT
Design the automated sorting and stacking system to need the manufacturing industry in
many fields is a very complex process. The system needs to develop in order to meet the
industry Satisfactions. Currently, this system is used for single purpose.
The main contribution of this project is to improve the current parts sorting and stacking
system in manufacturing industry. The investigation was made in scope of the lacking in
current parts sorting and stacking system in manufacturing industries. The step of
development of the project starts with survey the manufacturing current scenario, analysis
the current sorting system, development of concept design and development of the detail
design using the engineering software called Automation Studio software. Designed and
analyzed the concept design using simulation in order to get the detail results. The detail
results shows that the designed system can encounter the problem that current automated
sorting and stack faced. The outcomes of this the semester project can be used as reference
to support in developing the automated sorting and stacking systems in future.

Contents

CHAPTER 1 INTRODUCTION.......................................................................................1
1.1Background and rationale..............................................................................................1
1.2 Sstatement of problem...2
1.3 Objective of the study...................................................................................................3
1.4 Scopes and limitation3
1.5 Significance of the study .4
1.6 Framework of the study..4
CHAPTER 2.LITERATURE REVIEW..5
2.1 Introduction...5
2.2 Sorting and stacking system components.....................................................................5
2.2.1 Induction motor..........................................................................................................5
2.2.2
2.2.2.1.
2.2.3.

Pneumatics system................................................................................................5
Electro-pneumatic system..................................................................................6
Pneumatic valves..................................................................................................6

2.2.4. Single acting Cylinders (spring return).....................................................................6

2.2.5. Double acting cylinder............................................................................................6
2.2.6 Conveyor system........................................................................................................7
2.2.6.1 Pneumatic conveyor systems..................................................................................8
2.3 Application of Automated Sorting and stacking Systems.............................................8
2.4 Advantages and Disadvantages.....................................................................................9
CHAPTER 3 METHODOLOGY..10
3.1 MATERALIS..............................................................................................................10
3.1.1.

Use of Electro-pneumatic system......................................................................10

3.1.1.1. Advantageous of Electro Pneumatic System........................................................10

3.1.1.2 Disadvantageous of Electro-pneumatic system..................................................10
3.1.2. Supply elements....................................................................................................11
3.1.3.

Relay....................................................................................................................13

3.1.3.1. Types of contacts...............................................................................................13

3.1.3.2.

Overload relays................................................................................................13

3.1.4. Sensors....................................................................................................................13
3.1.4.1.

Proximity sensors..............................................................................................14

3.1.4.2. Advantages of proximity sensors are:-..............................................................14

3.1.4.3. Disadvantages of proximity sensors are:-............................................................14
3.1.5. Push button switches...............................................................................................14
3.1.6

Solenoids.............................................................................................................15

3.2 METHODS.................................................................................................................15
3.2.1 The design................................................................................................................15
3.2.2 The development and integration...19
3.2.3 The simulation..........................................................................................................20
CHAPTER 4. RESULTS AND DISCUSSIONS..23
4.1. Results and Discussions.............................................................................................23
CHAPTER FIVE 5. CONCLUSIONS, RECOMMENDATION AND FUTURE
WORK...28
5.1 Conclusion...................................................................................................................28
5.2 Recommendations.......................................................................................................28
5.3. Future Works..............................................................................................................29
REFERENCES..................................................................................................................29

List of tables
Table 1.1: Framework of the study..4
Table 3.1 the I/O devices utilized in the system.18
Table 3.2: The initial motion sequence diagram..20
Table 3.3: The continuation motion sequence...................................20
Table 4.1: The motion sequence diagram.....23
List of figure

Figure 1.1 control system frame work4

Figure 2.1: Visual classification setup in an industrial setting .8
Figure 3.1 input output model..12
Figure 3.2The motor-driven conveyor..16
Figure 3.3: The linear feeder actuators.16
Figure 3.4: The materials detection representation..17
Figure 3.5The storage/stacking area17
Figure 3.6 The input-output devices PLC interface..18
Figure 3.7 sorting and stacking system framework.19
Figure 3.8 control circuit ladder diagram ..22
Figure 3.9 power circuit ladder diagram22
Figure 4.1The sorting and stacking system framework/ the input-output devices PLC
interface/ the materials detection representation of output results24
Figure 4.2 The control circuit PLC ladder program output result25
Figure 4.3 The power circuit PLC ladder diagram program output result...26

Abbreviation
ASRS

Automatic storage and retrieval system

IEC

International Electro technical Commission

I/O

Input output

NC

Normal closed

NO

Normal open

PLC

Programing logic control

RST

reset

CHAPTER 1
INTRODUCTION
1.1Background and rationale
Sorting and stacking systems are required in many industrial fields such as in
manufacturing industry (soft drinking companies) to make sure the manufacturing
process more efficiently. All sorting and stacking processes, although different,
generally consist of looking at the objects distributed on moving conveyor, localizing
any single part, recognizing the relevant features that make it acceptable or not and
separated the parts depend on their categories. The automated sorting and staking
systems are similar with the manual sorting and stacking systems. The difference
between those two is that the automated sorting and stacking system is more efficient
and used more technology features intargeted into their system than the manual
sorting and stacking. Another name of automatic sorting and stacking system is
popularly known in advanced manufacturing industry as the automatic storage and
retrieval systems. An automated storage (stack) and retrieval (sort) system (ASRS or
AS/RS) consists of a variety of computer controlled systems for automatically
placing and retrieving loads from defined storage.
The technology of interest has significant impact on various economic sectors.
Automatic sorting and stacking systems are developed for automatic storage and
retrieval of parts in manufacturing, distribution, retail, wholesale and institutions
through engineering the use of micro-controller-based control system. Automatic
sorting and stacking system typically used in application where there is a very high
volume of loads being move in and out of storage. The system is needed to be
developed in order to meet the industry customer satisfaction. However, the
significant impact of the technology also posed some challenges and problems. In
most industrial situations where a sorting and stacking process is needed, a highly
structured environment can be found, specifically designed for the optimal
exploitation of system capabilities. In order to accomplish fully automated parts
sorting and stacking systems, some problems are identified in the following areas as

experienced by various industries like the automatic storage in the stacking without
overlapping materials, classification of a various materials and its automatic
identification, and optimization of the separation strategy in order to upgrade the
performance the system.
The above mentioned problems identified in the baseline research on the utility of
sorting and stacking technology also have identified alternatives and solutions as
initiated by other industry practitioners. The problem occurs because of the sorting
and stacking systems that has been used are really not suitable in manufacturing
industry current scenario. Besides that, it happened when the system is not meeting
the manufacturing industry desired needs and purpose. This sorting and stacking
system is not only focusend on the system but also focusend on the part or equipment
that has been used. Some system was developed based on the manual sorting
conveyor utilized by some traditional manufacturing industry. On this type of
conventional conveying system, poor quality materials are manually removed from
the packing line, leaving only the good quality manufacturing industry product to
continue the packing process..
The aforementioned arguments are worthwhile baseline research that provides
significant influence to the conduct of this present study. As such provides motivation
to initiate an innovative sorting and stacking concept through modelling and
simulation. Hence, the conduct of this study may be helpful to some relevant
industries in the manufacturing field.
1.2 statement of problem
The design and simulation of automatic sorting and stacking system provides better
benchmark model for further implementation in the local industry in Ethiopia, Africa
in an effort to mitigate problems in the manufacturing industry. Automatic sorting and
stacking system enables the useful arrangement of products in suitable order and
storing suitable localization by using intelligent system. The design and development

of this automatic sorting and stacking system will preserve quality products through
autonomous control. The study therefore seeks to address the following questions:
1. What design parameter that has to be considered relative to the conveyor,
linear actuators, sensors, and control framework of the automated sorting and
stacking system?
2. What development strategy to be adopted in the integration of the sub-system
designs?
3. What simulation techniques and programming approach that has to be utilized
to effectively model the system?
4. What evaluation parameters to consider in measuring the performance and
acceptability of the project?

1.3 Objective of the study

The general objective of this study is to design and simulate an automatic sorting and
stacking system for the manufacturing industry in Ethiopia. The specific objectives
are:
a. To design the automated sorting and stacking system using a combination of
conveyor, linear pneumatic actuators, proximity sensors, and programmable logic
control.
b. To develop and integrate the sorting and stacking system using the design
parameters established.
c. To simulate the sorting and stacking system using the Automation Studio
software.
d. To evaluate the performance and acceptability of the sorting and stacking
machine using descriptive statistics.

1.4 Scopes and limitation

The premise of this study involves the modelling and simulation of a basic automated
sorting and stacking system utilizing conveyor, linear pneumatic cylinders, sensors,
and programmable logic control. The scope of this present study is exclusively done
through simulation and that implementation of physical components and system is
inhibited.
1.5 Significance of the study
The study will have significant contributions to the manufacturing industry to have
well established sorting and staking system that facilitates it to provide better services
to its customer. Furthermore; the study can be used with small adaptation in similar
Ethiopian manufacturing industries. The study is also valuable for further and better
research.
1.6 Framework of the study
The framework of the study utilizes the inputprocessoutput paradigm as shown in
Table 1.1 where the baseline researches, benchmark information, and input devices
are classified into the input variable. Baseline research synthesis, circuit
development, PLC programming are processed, and the output of the study is
expected to produce the model sorting and stacking system. Figure 1 also shows the
control framework of the automated system.
Table 1.1: Framework of the study
input
process
Automation
Studio
Automation Studio
Software
Programming
and Interfacing

Out put
Automatic sorting and

simulation, pneumatic

simulation,

stacking

valve sensor/switch

programing

PLC

system

model, skill set in

simulation ,PLC

Input Devices
System Processor
Output Devices

Figure 1.1: Control system framework

CHAPTER 2
LITERATURE REVIEW

2.1 Introduction
There several issues regarding to the usage of automated sorting systems in
manufacturing industries. These problem occurs because of the sorting systems that been
used are really not suitable in manufacturing industry current scenario. Beside that, it
happened when the system is not meeting the manufacturing industry desired and needed.

For this purpose, many parties try to develop the automated sorting and stacking system
that only capable to fulfill the task of manufacturing but also easier to operate and to
handle. This sorting and stacking system is not only focus on the system but also focus on
the part or equipment that been used.
2.2 Sorting and stacking system components
The following is detailed discussion of the major piece or section of the sorting and
stacking system components.
2.2.1 Induction motor
Induction motors are the most widely used motors for appliances, industrial control, and
automation; hence, they are often called the workhorse of the motion industry. They are
reliable, and durable. When power is supplied to an induction motor at the recommended
specifications, it runs at its rated speed. Motor cable size will be depending on the current
value of the motor.

2.2.2
Pneumatics system .
Pneumatic refers to any system or machine that is moved using gas pressure .pneumatic
systems store energy in compressed gas and use the energy to perform tasks as the gas is
allowed to expand. A pneumatic system can be controlled either manually or automatically.
In manual control systems, operation is sequenced by operator who decides which action to
take. In automatic control systems, operation is sequenced by controller that automatically
decides each action to be taken. Automatic control can be accomplished by means of
electrical and pneumatic signals.
2.2.2.1.

Electro-pneumatic system

The most used pneumatic actuation systems are electrically controlled system.
These system are called electro-pneumatic control system is a combination of electrical
unit and pneumatic control unit both in one unit. In electro pneumatics, solenoid operated
directional control valves, limit switches and pressure switches are used on an automation
system one can find three families of components, which are sensors, valves and actuators.
A solenoid is used in pneumatic valves to acts the actuating element. Electro pneumatics is
now commonly used in many areas of Industrial low cost automation.
They are also used extensively in production, assembly, pharmaceutical, chemical and
packaging systems. There is a significant change in controls systems. The programmable
logic controllers have increasingly replaced relays in order to meet the growing demand for
more flexible automation.
2.2.3.

Pneumatic valves

Pneumatic valve is a device consisting of aluminum or brass body and an internal moving
part, which controls the movement of air within the valve body. In other words pneumatics
valves are devices to control direction of flow or rate of flow or pressured of the
compressed air
2.2.4. Single acting Cylinders (spring return)

Single acting cylinders (spring return) is a type of cylinder in which air pressure applied to
the piston to drive it in one direction.
2.2.5. Double acting cylinder
Double acting cylinder is a cylinder in which air pressure maybe alternately applied to the
piston to drive it in either direction.

2.2.6 Conveyor system

A conveyor system is a common piece of mechanical handling equipment that
moves materials from one location to another. Conveyors are especially useful in
applications involving the transportation of heavy or bulky materials. Conveyor systems
allow quick and efficient transportation for a wide variety of materials, which make them
very popular in the material handling and packaging industries
Many kinds of conveying systems are available, and are used according to the various
needs of Different industries. There are chain conveyors (floor and overhead)[2] as well.
Chain conveyor consists of enclosed tracks, I-Beam, towline, power & free, and hand
pushed trolleys.
Conveyor systems are used widespread across a range of industries due to the numerous
benefits they provide.
Conveyors are able to safely transport materials from one level to another, which when
done by Human labor would be strenuous and expensive.
They can be installed almost anywhere, and are much safer than using a forklift or other
machine to move materials. In a system that uses precisely controlled belts, such as a sorter
system, regular inspections should be made that all belts are traveling at the proper speeds
at all times.
Types of conveyor systems
4.1 Pneumatic conveyor systems

4.2 Vibrating conveyor systems

4.3 Flexible conveyor systems
4.4 Vertical conveyor systems and spiral conveyors
4.5 Heavy duty roller conveyors
In our projects we use pneumatic conveyor system
2.2.6.1 Pneumatic conveyor systems
Every pneumatic system, would makes use of pipes or ducts called transportation lines that
carry mixture of materials and a stream of air. These materials are such as dry pulverized or
free flowing or light powdery materials like cement, fly ash etc. These materials can be
transported conveniently to various destinations by means of a stream of high velocity air
through pipe lines. Products are moved through various tubes via air pressure, allowing for
extra vertical versatility. Pneumatic conveyors are either carrier systems or dilute-phase
systems; carrier systems simply push items from one entry point to one exit point, such as
the money-exchanging pneumatic tubes used at a bank drive-through window. Dilute-phase
systems use push-pull pressure to guide materials through various entry and/or exit points
2.3 Application of Automated Sorting and stacking Systems
According to Bachelor BG, Braggins DW (1992) in their article, industrial
Applications require some sort and stack of automated visual processing and the
classification of items placed on a moving conveyor. A typical process comprises of: at
i. looking. on the conveyor via some type of sensor such as at the items prximet sensors
ii. Localizing any single item n.
iii. Classifying the item based on a set of features such as shape
iv. Performing the necessary action depending on the classifications made.

According to the H. I-sil Bozrna, H.ulya Yal-cin (2002) in their journal explains about a
Visual classification setup i n an industrial setting typical setup. The Figure 2.1 shows the
typical setupabout visual classification.

Figure 2.1: Visual classification setup in an industrial setting

From figure 2.1, the authors explain how to detect the items at randompositioned and
oriented on a conveyor. A camera located above the conveyor views the item
orthographically.
2.4 Advantages and Disadvantages
There several strength that have been identified with these part sorting system. The
Advantages are as follows:
a. The production rate of the manufacturing industry has been increased since
These sorting systems replaced the human resources.
b. The accidents in manufacturing industry can be prevented because the uses of
Operator in manufacturing floor had been reduced.
c. Current sorting system is available in various configurations and has the
Widest range of custom features and options to best suit the application.

CHAPTER 3
METHODOLOGY
The methodology of this present study is anchored on the design, development,
simulation and evaluation of the research-based project which is in conjunction with the
objectives of the study. Baseline research analysis is subsumed in the background and
rationale of the study.
3.1 MATERALIS
Materials have been used in this work are articles, and reference and text books, recognized
and regulated documents, softwares(PLC), internet, and personal computer
3.1.1.

Use of Electro-pneumatic system

The most used pneumatic actuation systems are electrically controlled system. These
system are called electro-pneumatic control system is a combination of electrical unit and
pneumatic control unit both in one unit. In electro pneumatics, solenoid operated
directional control valves, limit switches and pressure switches are used on an automation
system one can find three families of components, which are sensors, valves and actuators.
A solenoid is used in pneumatic valves to acts the actuating element.
Signal input devices-Signal generation such as switches and contactor, various types of
contact and proximity sensors. Signal Processing Use of combination of Contactors of
Relay or using Programmable Logic Controllers. Signal Out puts Out puts obtained after
processing are used for activation of solenoids, and indicators.
3.1.1.1. Advantageous of Electro Pneumatic System

10

The system allows easy automation of complex process. The high speed signal transmitting
and processing leads to a significance enhancement of the productivity of the automation
system. Significance loads are control with reduced control signal. The loading gauge of
control equipment is reduced. Electronic programmers and process computer are used for
control of the system.
3.1.1.2 Disadvantageous of Electro-pneumatic system
The system has two supply units (pneumatic and electric).
The function not allowed inflammable environments, in environments subjected to hazard
of explosion or in high humidity conditions.
3.1.2. Supply elements
We have to controlled pneumatic systems via pneumatic signals using pneumatically
actuated valves. It is possible to controlled pneumatic systems via pneumatic signals using
pneumatically actuated valves. Pneumatically controlled systems, signals are transmitted as
compressed air. Where as in electrically actuated systems, signals transmitted as electrical
current but still the cylinders are driven by compressed air to perform their duties.
So we expect to find sources of power in electro-pneumatic systems: compressors and
electrical power supplies. The electrical power supplies can be either dc or ac supplies but
we use ac power supplies of 24v in this system. In pneumatically controlled systems,
signals are transmitted as compressed air. Whereas in electrically actuated systems, signals
are transmitted as electrical current, still the cylinders are driven by compressed air to
perform their duties.
Therefore, we expect to find two sources of power in electro-pneumatic systems. Electropneumatic system is still pneumatic system in essence, which means that it has the main
four components of a pneumatic system?
Input elements
Processing elements

11

 Final control elements

Power elements (actuators

An important concept in electro-pneumatic systems is the ladder diagram. This diagram is a

graphical representation of the electrical part of the electro-pneumatic system. It reflects
our way of thinking. So in order to build an electro-pneumatic system, we have to start with
putting the ladder diagram. Ladder diagram is an important concept not only at electropneumatic systems, but also at PLC. Each ladder diagram is constructed from input
switches and out relays that lies between the positive and negative power lines

Figure
3.1

input
output

model
While the electrical parts are:

Pushbutton to control the start of the system

Pushbutton to control the stop of the system
Normally open contacts
Normally close contacts
Coils

The connecting of pneumatic circuit the connecting of pneumatic circuit

Connect each output part of each directional valve to the throttle valve. Connect each
throttle valve to each cylinder so that the port of the directional valve that is connected
to the pressure source is connected to a part that is responsible for retracting the piston

12

through the throttle valve while the other port directional valve connected to the
exhausted for moving the pressure out is connected to the cylinder through another
throttle valve. The input port of each directional valve which is responsible of retracting
the piston connected to the compressor. The port of directional valve, which is
responsible of moving out the pressure from the other side of piston, connected to the
exhaust. The compressor is connected to the pressure source

3.1.3.

Relay

An associated concept with relays is the normally open and normally closed contacts. A
relay is an electro magnetically actuated switch. It is a simple electrical device used for
signal processing. Relays also possess interlocking capability that is an important safety
feature in control circuits. Interlocking avoids simultaneous switching of certain coils.
3.1.3.1. Types of contacts
The name of the contact comes of its natural (normal) physical state when the relay's
Coil is not actuated. As long as the coil of the relay is not activated (no current is flowing
through it), then the spring force will keep the contacts in their positions. Once the coil is
activated (energized) the contacts will change their physical stat. Thus the normally open
contact will become closed and the normally closed contact will become Open. As we said
above, the inputs can be electrical push buttons or proximity switches. Proximity switches
can be: inductive, and capacitive.
3.1.3.2.

Overload relays

Overload relays are provided to protect motors, motor control apparatus and Motor-branch
circuit conductors against excessive heating due to motor overloads and failure to start.
3.1.4. Sensors
Inductive sensor use currents induced by magnetic field to detect the nearby metal objects.
The inductive sensor uses a coil or inductor to generate a high frequency magnetic field. If

13

there is a metal object near the changing magnetic field, current will flow in the object.
This resulting current flow sets up a new magnetic field that opposes the original magnetic
field. The net effect is that it changes the inductance of the coil in the inductive sensor. By
measuring the inductance the sensor can determine when a metal have been brought
nearby. These sensors will detect any metals, when detecting multiple types of metal
multiple sensors are used. The sensors can detect objects a few centimeters away from the
end. The switching distance of inductive sensors depends on the conductivity and
permeability of the metal part whose presence or absence to be detected. Capacitive
proximity sensors are similar to inductive proximity sensors.

3.1.4.1.

Proximity sensors

The proximity sensor reacts to the presence of objects disturbing the magnetic field emitted
by the sensor. Placed against an aluminum cylinder, it reacts to the passage of the steel rod.
The switch is then closed and an electrical signal activates the component from the
electrical diagram associated with this sensor.
The proximity sensors can be used for various applications, these include:
Sensing of end position of linear actuators like cylinders and semi rotary
actuators .Inductive Proximity Sensors detect metal objects without touching them.
3.1.4.2. Advantages of proximity sensors are: They are self-contained, rugged and extremely reliable
They have long service life
They have shorter switching time
They are suitable for detecting nonmetallic objects
3.1.4.3. Disadvantages of proximity sensors are:-

14

They cannot be used in environments subjected to magnetic fields ( like resistance

welding machine)
They are sensitive especially in humid environment
Without the compensator ring, the sensor would be very sensitive to dirt, oil
and other contaminants that might stick to the sensor
3.1.5. Push button switches
A push button is a switch used to close or open an electric control circuit. They are
primarily used for starting and stopping of operation of machinery. They also provide
manual override when the emergency arises. Push button switches are actuated by pushing
the actuator into the housing. This causes set of contacts to open or close.
The contact of the push buttons, distinguished according to their functions,
i) Normally open (NO) type
ii) Normally closed (NC) type

3.1.6

Solenoids

Electrically actuated directional control valves form the interface between the two parts of
an electro-pneumatic control. The most important tasks of electrically actuated DCVs
include.
i) Switching supply air on or off
ii) Extension and retraction of cylinder drives
Electrically actuated directional control valves are switched with the aid of solenoids. They
can be divided into two groups:
i)

Spring return valves only remain in the actuated position as long as current
flows through the solenoid

15

ii)

ii) Double solenoid valves retain the last switched position even when no
current flows through the solenoid.

3.2 METHODS
The design, the development and integration and simulation are the methods used. The
following sections present each of these in detail.
3.2.1 The design
The building blocks of the design are composed of the motor-driven conveyor, the linear
pneumatic feeder cylinders, materials detection sensors, the stacking confirmation sensors,
the PLC input-output interfacing, and the systems motion sequence diagram.

The

conveyor system utilizes a three-phase motor prime mover as shown in Figure 3.1 which
has a unidirectional rotation as the conveyor belt only rotates in forward direction to
transfer materials into the stacking and sorting storage area. The motor is controlled
through an external relay contacts (Q0) in which its corresponding coil is interfaced into the
PLC input/output modules.

Figure 3.2: The motor-driven conveyor

The linear pneumatic feeder actuators

16

The materials transferred through the conveyor belt are appropriately sorted by the linear
pneumatic cylinders shown in Figure 3.2 so positioned in such a way that the materials are
stacked in the desired storage area until it is fully loaded into it. The actuation of each
cylinder depends upon the incoming material detection using proximity sensors S8 and S9.

Figure 3.3: The linear feeder actuators

The materials detection
The materials detection is simulated by using two single-acting cylinders and a pair of
proximity sensors to demonstrate the transfer materials-detection. As shown in Figure 3.3,
every actuation of the cylinders represents one single material detection by the proximity
sensors S8 and S9 respectively. When the rod-end of the cylinders is detected by the sensor,
a consequent activation of the feeder cylinder takes place. The two linear cylinder rod-ends
represent the materials traversing on top of the conveyor belt as it passes in proximity to the
feeder actuators Q1 and Q2.

17

Figure 3.4: The materials detection representation

The storage/stacking area
The storage area is composed of two tandem stacking lane attached with two corresponding
proximity sensors S6 and S7 as confirmation of a fully-stacked status as shown in Figure
3.5. These sensors serve as triggering switch that prompts the feeder actuators to cease
storage on the particular storage lane.

Figure

3.5:

The

storage/stacking area
The

input-output

devices-PLC

interfacing
All the input and output devices of the system are appropriately connected into the PLC
input/output (I/O) modules as shown in Figure 3. 6.

18

Figure 3.6: The input-output devices PLC interface

Table 3.1 depicts the complete detailed description of the I/O devices utilized in the
system.
input device

output device

S0 Start Button

Q0 Motor contactor

S1 Stop Button

Q1 Feedercylinder1

S2 Proximity Sensor

Q2 Feedercylinder2

S3 Proximity Sensor
S4 Proximity Sensor
S5 Proximity Sensor
S6- StackedMaterialDetectionSensor_1
S7 StackedMaterialDetectionSensor_2
S8 Entry Material Detection Sensor_1
S9 - EntryMaterialDetectionSensor_2

19

3.2.2 The development and integration

The building blocks of the design are integrated to form the whole systems framework as
shown in Figure 3.6. The aforementioned figure depicts the integration of the sub- systems
of the whole framework which consists of the conveyor system, feeding actuators, storage,
and material detects.

Figure 3.7 sorting and stacking system framework

3.2.3 The simulation
The systems simulation is conducted using the Automation Studio software. The integrated
design is subjected to the careful modeling and simulation in adherence to a scientific
method of PLC programming aided by the systems motion sequence diagram. This motion
sequence diagram serves as guide for the programmer to create and develop the PLC ladder
program specifically in building up the control and power control framework. The motion
sequence describes the series of activation and de-activation of output devices (Prefix Q
addresses) triggered appropriately by its corresponding input devices (Prefix I addresses).
Table 3.2 and Table 3.3 show the initial and continuation motion sequences.
Table 3.2: The initial motion sequence diagram

20

I2&I

Q0

Q1

Q1

Q1

Q1

Q1

Q1

Q1

Q1

Table 3.3: The continuation motion sequence

I2&I9

I9
Q2+

Q2-

I5

I9
Q2+

Q2-

I5

I9
Q2+

Q2

Q2-/Q0-/R

ST
I7

The PLC ladder program utilizes a scientific method of programming approach.

There are scientific steps that are followed in the PLC ladder programming which adheres
to the prevailing International Electro technical Commission (IEC) standard IEC 1131, to
wit:
1. Each control steps shall be represented by a unique relay address and should be selflatched.
2. The first step of the sequence shall bear the startup button connected in series with a
normally closed interlocking contact. This step should be represented by a unique relay
address and self-latched.

21

3. The proceeding control steps shall bear the triggering switches/sensors connected in
series with a step marker (the normally open contact address of the previous step relay
representation address). These proceeding steps should still be represented by relays and
self-latched.
4. The last step of the control circuit which is the RST shall also be represented by a relay
but may not be self-latched. The contact of the relay representing the RST shall be the
address used in the interlocking contact mentioned in the first step of the control circuit.
5. The power circuit shall bear the appropriate control step representations of output
component activation and deactivation. Say Q0+ represented by a normally open contact
shall be connected to a normally closed contact of the Q0- step. This series combination of
normally open (NO) and normally closed (NC) contacts shall be connected to the output
component (solenoid coil). The same treatment to the other output components activation
and DE-activation.
Based on the above mentioned scientific guidelines and the stipulated motion sequence, the
following PLC ladder program shown in Figure 3.8and Figure 3.9

22

Figure 3.8 control circuit ladder diagram

figure3.9 power circuit ladder diagram

23

CHAPTER FOUR
4. RESULTS AND DISCUSSIONS
In this chapter the results of the design of Automatic sorting and stacking system is
presented .the design of Automatic sorting and stacking system, which used to arranging
and storing the produced products with a short period of time and its advantageous to the
manufacturing industry . As mentioned in eerily and anthill at this time the manufacturing
industry is processed by operators .this mated is time losing and in efficiency. The results
of the investigation will be presented in the following paragraphs.
4.1. Results and Discussions
The monthly average and the yearly average products of the manufacturing industry
system by using human labor force product loss, together with other related data such as,
time consumption; product loss due to the absence of modern automatic sorting and
stacking system; etc. by considering the disadvantageous of the above mentioned problem.
We design the best automatic sorting and stacking system that can arranging and storing
within short period of time. The input that was fed into the PLC software is previously
mentioned.
I2&I9

Table 4.1: The motion sequence diagram

I

I2&I

Q0

Q1

Q1

Q1

Q1

Q1

Q1

Q1

Q1

24

STO
P

I2&I9

I9
Q2+

Q2-

I9
Q2+

Q2-

I9
Q2+

Q2-

Q2+

Q2-/
Q0-/
RST

I5

I5

I5

I5

The output of the project shown below

Figure 4.1: The sorting and stacking system framework/ the input-output devices PLC
interface/ the materials detection representation of output results.

25

Figure 4.2: The control circuit PLC ladder program output result

26

Figure 4.3: The power circuit PLC ladder diagram program output result
The general operation of the above system can be described as follows:
The input components are push button (normal closed and normally open) that are used to
start and stop the total system .That means when we press S0 push button S1 is normally
closed then due to the current flow from power source to motor therefore, M0 will energize,
closing the normally-open auxiliary contact in parallel with that switch.
M0 is permanently energized. Because of M0 is energized then output relay M1 is also
energized when M0 is energized

motors (Q0+) rotate continuously at the same time the

cover belts control (Q0) can start to operate.

27

On the other hand due to the M1 energized. At the same time M2 also energized due to the
sensor (S3), S3 is now cylinders 1 (Q1+) extended forward. At the same time sensor (s2)
energized, s2 is now cylinder 1 (Q1-) extended backward. Then the system continually
works until four times the cylinder 1(Q1+ and Q1-) extended forward/back ward. After that
sensor(S6) is energized .at the same time M9 also energized due to the sensor(S5),S5 is
now cylinder 2(Q2+) extended forward .At the same time sensor(s4) energized,S4 is now
cylinder 2(Q2-) extended backward. Then the system continuously works until S7 is
activated (that manse the cylinder2 (Q2+ andQ2-) is extended for ward and back ward four
times).finally S7 is activated the overall the system is stop (i.e. S7 communicating to S9
(entry Material Detection Sensor_2) at the same time Q0-/Q2-/RST is activated finally the
system is stop.

28

CHAPTER FIVE
5. CONCLUSIONS, RECOMMENDATION AND FUTURE WORK
5.1 Conclusion
This project discussed about the way of automatic sorting and stacking system which
includes induction motor, cover, stacker (storage), other electro pneumatic components and
mechanical parts and its principle operations.
This way of automatic sorting and stacking system is supposed to increase the productivity
of soft drinking products in manufacturing industry. The merchant also it is better to use
this system and they can export good quality soft drinking products to local customers and
global markets. The soft drinking product system is very essential for hotels, restaurants,
commits and all over the country area. Mainly this automatic sorting and stacking system
have a great for the quality productivity of our country industrial process.
Generally this way of automatic sorting and stacking system is very important to get quality
product in industrial products; therefore it increases the annual amount of soft drink
products in our country.
5.2 Recommendations
The following recommendations are made from this project:Even if there is shortage of electrical power to use this automatic sorting and stacking
system technology in industrial city parts of Ethiopia. It is possible to use solar energy
source and wind energy source but most of the manufacturing industry may not use this
system because of lack of electrical energy therefore the government and private sectors
should exert their combined effort to overcome these challenges and electrify
manufacturing industry areas. This automatic sorting and stacking system for the selected
site can be implemented if the materials are available. For industrial area communities that
have not enough electricity or other industrial places which are far from the grid system it
is better to use solar panel and wind energy source.

29

In order to solve the absence of electrical energy in industrial area, Because of the high cost
of day to day diesel price. Therefore it is advisable to use the solar energy and wind energy.
5.3. Future Works
The future works of the automatic sorting and stacking system are:
This automatic sorting and stacking system works only 8 soft drinking products at the same
time with one labor as operates because of this in future increasing the detector circuit,
increase number of double acting cylinder, increasing the control circuit, powercircuit and
number of directional valve to increasing the number of soft drinking products at the same
times with one
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