DESIGN AND IMPLEMENTATION OF PLC-BASED

AUTOMATIC PACKAGING AND STAMPING MACHINE

by
INJAMUL ALAM
MUHAMMAD ABRAR MAHMUD CHOWDHURY

BACHELOR OF SCIENCE IN ELECTRICAL AND ELECTRONIC

ENGINEERING

Department of Electrical and Electronic Engineering

INTERNATIONAL ISLAMIC UNIVERSITY CHITTAGONG

MAY 2018
 DESIGN AND IMPLEMENTATION OF PLC-BASED
AUTOMATIC PACKAGING AND STAMPING MACHINE

by

INJAMUL ALAM
MUHAMMAD ABRAR MAHMUD CHOWDHURY

A project
Submitted as partial fulfilment of the requirement for the degree of

BACHELOR OF SCIENCE IN ELECTRICAL AND ELECTRONIC

ENGINEERING

Department of Electrical and Electronic Engineering

INTERNATIONAL ISLAMIC UNIVERSITY CHITTAGONG

MAY 2018
 CERTIFICATE OF APPROVAL

The thesis/project entitled as “Design and Implementation of PLC-Based Automatic

Packaging and Stamping Machine” submitted by Injamul Alam, bearing Matric ID.
ET133013 and Muhammad Abrar Mahmud Chowdhury, bearing Matric ID.
ET133017of session May 2018, to the Department of Electrical and Electronic
Engineering, International Islamic University Chittagong, has been accepted as
satisfactory in partial fulfilment of the requirements for the degree of Bachelor of
Science in Engineering and approved for the examination held on 19 May, 2018.

Supervisor
Engr. Rashidul Islam
Assistant Professor,
Department of Electrical and Electronic Engineering
International Islamic University Chittagong.

ii
 DECLARATION

It is hereby declared that this work has been done by us and no portion of the work
contained in this thesis/project has been submitted elsewhere for the award of any
degree or diploma.

____________________
Injamul Alam

___________________________________
Muhammad Abrar Mahmud Chowdhury

iii
 ACKNOWLEDGMENT

All praises and thanks to Allah, the Lord of the world, the most Beneficent, the
most Merciful for helping us to accomplish this work.
We are beholden to a number of people, who supported us to carry out this
work. We are truly indebted and wish to express our gratitude to our supervisor Engr.
Md. Rashidul Islam, Assistant Professor of Department of Electrical and Electronic
Engineering, for his inspiration, excellent supervision, continuing encouragement,
unwavering confidence, and support in every stage of this project work, without which
it would not be possible for us to complete the project work successfully. We also thank
him for his insightful comments and suggestion which continually inspired me to new
dimensions of research. We would like to express our thanks to Head of the
department, all the faculty members, staff of the Department of Electrical and
Electronic Engineering, who have rendered valuable help in making this project a
successful one.
Moreover, we would finally like to thank our parents, family, friends, and all
others for their support, help and faith in us.

Authors

iv
 ABSTRACT

In the modern days with the development of technology, the application of automation
in industrial sector is increasing rapidly with each passing day. In the industrial sector
the importance of accuracy of quantitative packaging and proper stamping with sealing
cannot be neglected. The reduction of production cost and time depends greatly on the
proper way of accurate packaging along with stamping and sealing. Most modern
manufacturers adopted the technology of automatic packaging and sealing system. The
automation of packaging and sealing has become easier with the introduction of
programmable logic controller (PLC).
Therefore this project work deals with the design and implementation of a model of an
automatic packaging along with stamping and sealing process using PLC. The main
idea of this project is to design and fabricate a small and simple robotic arm to push the
object on production line and automate the process of stamping the expiry date or other
information regarding the product and packaging of a triangular box. Sensors were used
to send the information to the controller. This project can be used for industrial purpose
with some improvement. The main advantage of this system is that, it reduces human
efforts in the industrial production process and therefore significant reduction in
production cost is achieved.

v
 TABLE OF CONTENTS

CERTIFICATE OF APPROVAL ii
DECLARATION iii
ACKNOWLEDGEMENT iv
ABSTRACT v
TABLE OF CONTENTS vi
LIST OF TABLES ix
LIST OF FIGURES x

CHAPTER 1 INTRODUCTION 01
1.1 Background 01
1.2 Problem Statement 01
1.3 Objective 01
1.4 Thesis Outline 02

CHAPTER 2 Literature Review 03

2.1 Introduction 03
2.2 History of Automation 03
2.3 Evolution of PLC 03
2.3.1 Relays 03
2.3.1.1 Problems with Relays 04
2.3.2 Emergence of PLC Solution 04
2.4 Related Work 05
2.4.1 PLC Based Traffic Control System with Emergency Vehicle 05
Detection and Management
2.4.2 Processing and Packaging Automation System 07
2.4.3 PLC – Based Substation Automation and SCADA System and 07
Selecting a Control System Integrator
2.4.4 PLC Controlled Automatic Food Packaging Machine 08

CHAPTER 3 METHODOLOGY 09
3.1 Introduction 09
3.2 Components 09
3.3 Programmable Logic Controller (PLC) 09
3.3.1 Operation of PLC 10

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 3.3.2 Advantages of PLC 11
3.4 Limit Switches 11
3.4.1 Categories of Limit Switches 11
3.4.2 Advantages of Limit Switch 12
3.4.3 Disadvantages of Limit Switch 12
3.5 Proximity Switch 12
3.5.1 Features 13
3.5.2 Specification 13
3.5.3 Operation 14
3.6 Photo Sensor 15
3.6.1 Operation 15
3.6.2 Advantages 15
3.6.3 Disadvantages 16
3.7 Relay 16
3.7.1 Operation 17
3.7.2 Basic Parts 17
3.7.3 Types of Relay 18
3.7.4 Advantages 19
3.7.5 Disadvantages 19
3.8 DC Motor 20
3.8.1 Principle 20
3.9 DC Power Supply 21
3.10 DM 230R 21
3.10.1 Advantages 21
3.11 Functional Block Diagram of the Project 23
3.12 Circuit Diagram 24
3.13 Flowchart for the Designed Project 25
3.14 Hardware Implementation 26
3.15 Packaging Machine Structure 26
3.16 Loading the Program into PLC 26
3.17 Working of the Entire System 26
3.18 Software Used 26
3.19 Ladder Diagram 27

CHAPTER 4 RESULT AND DISCUSSIONS 30

4.1 Introduction 30
4.2 Sensor Performance 30
4.3 Overall Performance 30
4.4 Cost Analysis 31
4.5 Advantages 31
4.6 Limitation 31

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4.7 Application 31
4.8 Discussion 31

CHAPTER 5 CONCULSIONS AND FUTURE WORK 33

5.1 Conclusions 33
5.2 Future Improvement 33

REFERENCES 34

viii
 LIST OF FIGURES

Fig. 2.1 PLC based automatic traffic signals 06

Fig. 2.2 Main status screen of substations 07
Fig. 2.3 Block diagram of PLC Controlled Automatic Food Packaging 08
Machine
Fig. 3.1 Siemens logo PLC 10
Fig. 3.2 Siemens Logo PLC (with extension module) 10
Fig. 3.3 Various Types of Limit switch 12
Fig. 3.4 Proximity switch 13
Fig. 3.5 Photo sensor 15
Fig. 3.6 Relay 16
Fig. 3.7 Relay Diagram 17
Fig. 3.8 DC motor 20
Fig. 3.9 DC Power supply 21
Fig.3.10 Functional block diagram of an automatic packaging machine 23
Fig.3.11 Circuit Diagram of PLC – based Packaging and stamping machine 24
Fig.3.12 Design flow of this project 25
Fig.3.13 Ladder Diagram 29
Fig. 4.1 Packaging Machine Setup 30

ix
 LIST OF TABLES

Table 3.1 Specifications of Proximity Switch 13

Table 3.2 Specification of DM8 230R 22
Table 4.1 Cost Analysis 31

x
xi
 CHAPTER 1
INTRODUCTION

1.1 Background

Now a days, in the industrial sector, cost reduction has become a key factor for a
specific industry to grow. The higher production cost results in the loss of the numbers
of consumers. In order to reduce cost a very effective way is to reduce the labor cost
and reduce the working hour. The idea of industrial automation was introduced to
achieve these goals. With the beginning of the use of PLCs the industrial automation
process has become easier, cheaper and simpler. Therefore to achieve faster and higher
accuracy in industrial production process at a cheap rate, industrial sector is adopting
automation.
A programmable logic controller (PLC), or programmable controller is an
industrial digital computer which has been ruggedized and adapted for the control of
manufacturing processes, such as assembly lines, or robotic devices, or any activity that
requires high reliability control and ease of programming and process fault diagnosis. In
case of automatic packaging machine often sensors are used to provide the information
to the controller. A sensor is a device that can measure some attribute of motion.
Whenever any object passes in front of it senses the movement of the object and send
information to the connected system accordingly.
1.2 Problem Statement
Quantitative and accurate packaging in industrial sector plays a vital role to reduce the
cost of consumer products. In the industrial sector often automatically using the setup
of a conveyer belt, motion sensors and a heating chamber. But with the increasing price
of commercial electric power using heating chamber is not so cost efficient. To avoid
the amount of total power consumption for packaging in this project the use of heating
chamber is avoided.
1.3 Objective
The objectives of this project are given below
 To design a PLC based packaging unit.
 To fully automate the processing of a finished consumer products.
To achieve more accurate and faster quantitative packaging unit.

1
1.4 Thesis Outline
Chapter 1: ‘Introduction’ includes the background, problem statement, objective and
thesis outline
Chapter 2: Includes ‘Literature Review’ discusses history and previous work related to
this project.
Chapter 3: Includes ‘Methodology’
Chapter 4: Includes ‘Result and Discussion’
Chapter 5: Includes ‘Conclusion’

2
 Chapter 2
Literature Review

2.1 Introduction
In the industrial sector automation is used for increasing accuracy, speed and
effectiveness. It is also employed to reduce production cost and the various risk factors.
The history of industrial automation, PLC and some related works are described in the
literature review.
2.2 History of Industrial Automation
The term ‘automation’ in the manufacturing sense was introduced by Ford Motor Co.
Vice president Delmer S. Harder in 1948. Industrial automation in manufacturing
entails the use of machines to carry out manufacturing processes with levels of speed,
consistency, stamina, and precision beyond the capacity of a human worker. The
machines can be powered using a multitude of methods including electrical, hydraulic,
mechanical, pneumatic and computer. The main benefits of manufacturing automation
include reduced production costs, improved quality and reliability, and decreased waste
[1].
2.3 Evolution of PLC
The PLC or Programmable Logic Controller has revolutionized the automation
industry. Today PLCs can be found in everything from factory equipment to vending
machines, but prior to New Year’s Day 1968 the programmable controller didn’t even
exist. Instead what existed was a unique set of challenges that needed a solution. In
order to understand the history of the PLC the problems that existed before PLC must
be understood.
2.3.1 Relays
Before the days of the PLC the only way to control machinery was through the use of
relays. Relays work by utilizing a coil that, when energized, creates a magnetic force to
effectively pull a switch to the ON or OFF position. When the relay is de-energized, the
switch releases and returns the device to its standard ON or OFF position. So, if
someone wants to control whether a motor was ON or OFF he/she could attach a relay
between the motor and the power source.

3
2.3.1.1 Problems with Relays
In the modern factories there are numerous motors operate at any instant. To control a
single machine one would need a huge network of ON/OFF switch. This would be a
logistical nightmare. All these relays had to be hardwired in a very specific order for the
machine to work properly, and haven’t forbade if one relay would have an issue, the
system as a whole would not work. Troubleshooting would take hours, and because
coils would fail and contacts would wear out, there was need for lots of
troubleshooting. These machines had to follow a strict maintenance schedule and they
took up a lot of space. If anyone wants to change something, He/ She would basically
have to redo the entire system. It soon became clear that there were problems installing
and maintaining these large relay control systems.
2.3.2 Emergence of PLC Solution
According to Dick Morley the undisputed father of PLC, PLCs were introduced on New
Year’s Day 1968 to remove the problems mentioned above and make the industrial
operational procedure more easy and simple [2]. To replace the relay system there were
some requirements listed by GM (General Motors) which include [3]
 A solid-state system that was flexible like a computer but priced competitively
with a like kind relay logic system.
 Easily maintained and programmed in line with the already accepted relay
ladder logic way of doing things.
 It had to work in an industrial environment with all its dirt, moisture,
electromagnetism and vibration.
 It had to be modular in form to allow for easy exchange of components and
expandability.
The programming look of the PLC required that it be easily understood and used by
maintenance electricians and plant engineers. As relay-based control systems evolved
and became more complicated, the use of physical component location wiring diagrams
also evolved into the relay logic being shown in a ladder fashion. The control power hot
wire would be the left rail, with the control power neutral as the right rail. The various
relay contacts, pushbuttons, selector switches, limit switches, relay coils, motor starter
coils, solenoid valves, etc., shown in their logical order would form the ladder’s rungs.
It was requested that the PLC be programmed in this Ladder Logic fashion. The first
PLCs had the ability to work with input and output signals, relay coil/contact internal

4
logic, timers and counters. Timers and counters made use of word size internal
registers, so it wasn’t too long before simple four-function math became available. The
PLC continued to evolve with the addition of one-shots, analog input and output
signals, enhanced timers and counters, floating point math, drum sequencers and
mathematic functions. Having built-in PID (Proportional-Integral-Derivative)
functionality was a huge advantage for PLCs being used in the process industry.
Common sets of instructions evolved into fill-in-the-blank data boxes that have made
programming more efficient. The ability to use meaningful Tag Names in place of non-
descriptive labels has allowed the end user to more clearly define their application, and
the ability to import/export the Tag Names to other devices eliminates errors that result
when entering information into each device by hand.
As the functionality of the Programmable Logic Controller evolved, programming
devices and communications also saw rapid growth. The first programming devices
were dedicated, but unfortunately the size of suitcases. Later, handheld programming
devices came into the picture, but soon were replaced with proprietary programming
software running on a personal computer. Automation Direct’s Direct SOFT, developed
by Host Engineering, was the first Windows-based PLC programming software
package. Having a PC communicating with a PLC provided the ability to not only
program, but also allowed easier testing and troubleshooting. Communications started
with the MODBUS protocol using RS-232 serial communications. The addition of
various automation protocols communicating over RS-485, DeviceNet, Profibus, and
other serial communication architectures have followed. The use of serial
communications and the various PLC protocols also allowed PLCs to be networked
with other PLCs, motor drives, and human to machine interfaces (HMI). Most recently
EtherNet and protocols such as EtherNet/IP (for Industrial Protocol) have gained
tremendous popularity.
2.4 Related Works
In this section some works which were done before related to automation will be
discussed. In industrial sector automation were done using various techniques. Many
projects were done before on industrial automation as well as on PLCs.
2.4.1 PLC based traffic control system with emergency vehicle detection and
management

5
This project was done by Shajnush Amir, Mirza Sarwar Kamal, Syeda Shabanm
Khanam and K.M.A Salam of North South University, Dhaka [4].
In this project an automated traffic control system was designed with a distinctive
attribute of emergency vehicle control. Upon being interrupted by an emergency signal,
the system automatically retains the state of the normal sequence and gives the
corresponding road a green light signal as long as the emergency signal is high. As soon
as the emergency signal becomes low, the system instantly jumps back to the retained
state of the normal sequence. Emergency Signal detection is RFID based. The system is
designed using Programmable Logic Controller (PLC) ladder logic program. The
system was implemented in a PLC simulated environment.

Fig. 2.1 PLC Based Automatic Traffic Signals [13]

Later, it was tested in a hardware prototype. The test results indicated that it can be
implemented in the real world without altering the original code. This PLC based
system can be used to replace the conventional traffic control system. By including
additional input and output modules into the PLC system, this system can be easily

6
extended to dynamically manage the traffic system of an entire city. Fig. 2.1 illustrates,
how a PLC based automated traffic signal works.
2.4.2 Processing and packaging automation systems
This paper work is done by Nitaigour P. Mahalik at College of Agricultural Sciences
and Technology California State University, Fresno, USA [5].
This paper reviews aspects of systems, standards and interfaces for the modern food
industry. It presents processing and packaging principles, methods, techniques,
standards, interfaces, and state-of-the-art technology. The primary purpose of this
paper is to update the information in this domain so that not only the novice
practitioner will gain much out of this review but the system integrators, researchers,
and the stakeholders as well. In addition, the paper covers recent advances in smart
packaging materials, the examples of nanotechnology in packaging, material handling
systems, application of robotics, non-destructive inspection methods, packaging
execution systems (PES), distributed control and automation systems, traceability,
and finally OMAC (Open Modular Architecture Controls) guidelines on software
standards and interfaces.
2.4.3 PLC Based Substation Automation and SCADA Systems and Selecting a
Control System Integrator
This project was done by Tom Wilson with Programmable Control Services Inc. (PCS)
and presented at The Western Electric Power Institute, Las Vegas, Nevada, USA [6].

Fig. 2.2 Main status screen of the substations [6]

7
In this project the automation of a substation using PLC was designed. Each substation
PLC in this project is tied to a power monitoring device through the PLC’s remote I/O
system. The load data from all point of delivery substations is logged OIT application to
file that Chelan PUD access at regular intervals. In this way all the necessary
information about any substation connected to the system can be gathered in no time
without little or no human effort.
In the Fig. 2.2 the main status screen connected to such a system is shown, where all
the necessary information regarding the substations is being updated at a regular
interval.
2.4.4 PLC Controlled Automatic Food Packaging Machine
This project was done by D.Kanimozh,, B.Nantheni Devi and T.Manochandar under the
supervision of Assistant Professor PG Scholar and Assistant Professor, CK College Of
Engineering & Technology, Cuddalore [7].
In this system, cables were used for connecting the inputs. A single machine performs
all the packaging functions. The system is totally an automated system with the aid of
automatic machines. It is mainly used increase the speed and accuracy and there is an
elimination of wires.
Fig. 2.3 shows the Block diagram of PLC Controlled Automatic Food Packaging
Machine.

Fig. 2.3 Block diagram of PLC Controlled Automatic Food Packaging Machine [14]

8
 Chapter 3
Methodology
3.1 Introduction
Since the purpose of this project is to design a fully automatic stamping and packing
machine, therefore any human interference during the operation of this system was tried
to be avoided. To achieve this primary goal a logo PLC was employed to control the
entire operation. Along with this a conveyer belt which is run by a single DC motor,
motion sensor and another DC motor to rotate the packing platform are used.
Conveyor passes the product through the sensor 1. When the product passes through the
sensor 1 the stamping unit gets activated and prints the necessary information on the
product. The product then passes through the sensor 2, when sensor 2 counts up to 4
products the packaging unit gets activated and palletize all those products together.
3.2 Components
In this project several types of components were used. They are
 Programmable Logic Controller (PLC)
 DM8 230R Module
 DC Motor (24V)
 Gear Motor (12V)
 Limit switches
 Proximity switch
 Photo Sensor
 Relay (24V DC)
 DC power supply (24V)

3.3 Programmable Logic Controller (PLC)

A Programmable Logic Controller, PLC or Programmable Controller is a digital
computer used for automation of electromechanical processes, such a control of
machinery on factory assembly lines, amusement rides, or light fixtures. PLCs are used
in many industries and machines. Unlike general-purpose computers, the PLC is
designed for multiple inputs and output arrangements, extended temperature ranges,
immunity to electrical noise, and resistance to vibration and impact. Programs to

9
control machine operation are typically stored in battery-backed-up or non-volatile
memory. Some PLCs are shown in Fig. 3.1

Fig. 3.1 Siemens Logo PLC [15]

Fig. 3.2 Logo PLC with Extension Module [15]

3.3.1 Operation of PLC

The operation of a PLC is very simple. The processor makes decisions based on a
ladder logic program written by the user. In order to use the program properly, the PLC

10
must communicate with the various field devices it is tasked with monitoring and
controlling. It then compares the actual conditions of the field devices with what the
program instructs them to do, and updates the output devices accordingly.
The operational sequence is as follows:
Input switch is pressed.
Input module places a “1″ in the input data table,
The ladder logic program sees the “1″ and caused a “1″ to be put into the output data
table.
The output data table causes the output module to energize associated point.
The output device energizes.
3.3.2 Advantages of PLC
 PLC is armored for severe conditions like dust, moisture, heat, cold, etc.
 Programming a PLC is easier than wiring the relay control panel.
 PLC can be reprogrammed. Conventional controls must be rewired and are
often crapped instead.
 PLC takes less floor space then relay control panels.
 A PLC has facility for extending input/output arrangements.
 Maintenance of the PLC is easier, and reliability is greater.
 Special functions such as time-delay actions and counters can be easily
implemented using PLC.
3.4 Limit Switches
A limit switch is an electro-mechanical device that consists of an actuator mechanically
linked to a set of contacts. When an object comes into contact with the actuator, the
device operates the contacts to make or break an electrical connection.
3.4.1 Categories of Limit Switches
Limit switches are also available in four unique categories: Global, Medium-duty,
Heavy-duty and Safety Locking an Unlocking Styles.[8] They are –
Global Limit Switch
Medium duty Limit Switch
Heavy duty Limit switch
Safety locking and unlocking styles
Some limit switches are shown in Fig. 3.3

11
 Heavy Duty Medium Duty

Global Safety locking and unlocking

Fig. 3.3 Various Types of Limit switch [16]

3.4.2 Advantages of Limit Switch

 High Current Capability
 Low Cost
 Familiar “Low- Tech" Sensing
3.4.3 Disadvantages of Limit Switch
 Requires Physical
 Contact with Target
 Very Slow Response
 Contact Bounce
 Vulnerable
3.5 Proximity Switch
Proximity switches (proximity sensors) provide contactless detection of an approaching
metal object. We offer a variety of induction-based proximity switches, which make use
of electromagnetic coupling to detect eddy currents generated in a metal target object. A
proximity switch is shown Fig. 3.4

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 Fig. 3.4 Proximity Switch [17]
3.5.1 Features
 Easy-to-use and tough
 Wide range of models
 Wide operating voltage range
 Short circuit protected
 Ideal for a variety of applications
 With a metal connector that can be tightened securely and a cord protector
 Enclosure rating of IP66, water-proof and oil-drip proof
 Fast response
3.5.2 Specifications
Table 3.1 Specifications of Proximity Switch
Item Standard
Differential travel 10% max. of sensing distance
Item Standard
Target Ferrous metal (The sensing distance
decreases with non-ferrous metal.)
Power supply voltage 12 ~ 24 VDC. Ripple (p~p): 10% max.
(operating voltage range) (10 ~ 30 VDC)
Current consumption (DC 3-wire) 10 mA max.
Control output
Load current 200 mA max. (32 VDC max.) 1 V max.
Residual voltage (under load current of 200 mA with cable
length of 2 m)

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Protection Output reverse polarity protection, Power
circuit source circuit reverse polarity protection,
Surge suppressor, Short-circuit protection
Ambient air temperature Operating: -40℃ to 70℃
Storage: -40℃ to 85℃ (with no icing or
condensation)
Temperature influence ±10% max. of sensing distance at 23℃
within temperature range of -25℃ to
70℃
±15% max. of sensing distance at 23℃
within temperature range of -40 to 70
Ambient humidity Operating: 35% to 95%, Storage: 35% to
95%
Voltage influence ±1% max. of sensing distance in rated
voltage range ±15%
Insulation resistance 50 M min. (at 500 VDC) between
current carry parts and case
Dielectric strength 1,000 VAC at 50/60 Hz for 1 min
between current carry parts and case
Vibration resistance 10 to 55 Hz, 1.5mm double amplitude for
2 hours each in X, Y and Z directions
Shock resistance 1,000 m/s2, 10 times each in x, Y and Z
directions
Standards and listings IEC60529: IP66, Degree of protection
EN60947-5-2: EMC

3.5.3 Operation
Inductive proximity sensors are used for non-contact detection of metallic objects.
Their operating principle is based on a coil and oscillator that creates an
electromagnetic field in the close surroundings of the sensing surface. The presence of a
metallic object (actuator) in the operating area causes a dampening of the oscillation
amplitude. The rise or fall of such oscillation is identified by a threshold circuit that

14
changes the output of the sensor. The operating distance of the sensor depends on the
actuator's shape and size and is strictly linked to the nature of the material.
3.6 Photo Sensor
A photoelectric sensor or photo sensor emits a light beam (visible or infrared) from its
light-emitting element. A reflective-type photoelectric sensor is used to detect the light
beam reflected from the target. A thru beam type sensor is used to measure the change
in light quantity caused by the target crossing the optical axis. A photo sensor is shown
in Fig. 3.5

Fig. 3.5 Photo Sensor (Omron) [18]

3.6.1 Operation
A Photoelectric Sensor consists primarily of an Emitter for emitting light and a
Receiver for 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.[3]
3.6.2 Advantages
Following are the advantages of photoelectric sensor
 It senses all kinds of materials.
 It has longer life.
 It has long sensing range and very reliable.
 It has very fast response time.

15
  It is less costly.
 Diffuse photoelectric sensor detects small objects including color mark and
label detection.
 Retro-reflective type can detect transparent objects.
 Thru beam type can detect long range and it is tolerant of dirty environment.

3.6.3 Disadvantages
Following are the disadvantages of photoelectric sensor
 Over coarse of time lens get contaminated.
 It's sensing range is affected due to color and reflectivity of the target.
 Thru beam type requires transmitter (Tx) and receiver (Rx) at two separate
locations.
3.7 Relay
Relays are switches that open and close circuits electromechanically or electronically.
Relays control one electrical circuit by opening and closing contacts in another
circuit. Relay is shown in Fig. 3.6

Fig. 3.6 Relay [19]

16
3.7.1 Operation
The diagram of a relay operation is shown in Fig. 3.7

Fig. 3.7 Relay Diagram [20]

As relay diagrams show, when a relay contact is normally open (NO), there is an open
contact when the relay is not energized. When a relay contact is Normally Closed (NC),
there is a closed contact when the relay is not energized. In either case, applying
electrical current to the contacts will change their state.
3.7.2 Basic Parts
Basic parts and functions of electromechanical relays include:
Frame: Heavy-duty frame that contains and supports the parts of the relay.
Coil: Wire is wound around a metal core. The coil of wire causes an electromagnetic
field.
Armature: A relays moving part. The armature opens and closes the contacts. An
attached spring returns the armature to its original position.
Contacts: The conducting part of the switch that makes (closes) or breaks (opens) a
circuit.
Break -This is the number of separate places or contacts that a switch uses to open or
close a single electrical circuit. All contacts are either single break or double break. A
single break (SB) contact breaks an electrical circuit in one place, while a double break

17
(DB) contact breaks it in two places. Single break contacts are normally used when
switching lower power devices such as indicating lights. Double break contacts are used
when switching high-power devices such as solenoids.
Pole -This is the number of completely isolated circuits that relays can pass through a
switch. A single-pole contact (SP) can carry current through only one circuit at a time.
A double-pole contact (DP) can carry current through two isolated circuits
simultaneously. The maximum number of poles is 12, depending upon a relays design.
Throw -This is the number of closed contact positions per pole that are available on a
switch. A switch with a single throw contact can control only one circuit, while a
double-throw contact can control two.
3.7.3 Types of Relay
General Purpose Relays are electromechanical switches, usually operated by a
magnetic coil. General purpose relays operate with AC or DC current, at common
voltages such as 12V, 24V, 48V, 120V and 230V, and they can control currents ranging
from 2A-30A. These relays are economical, easy to replace and allow a wide range of
switch configuration.
Machine Control Relays are also operated by a magnetic coil. They are heavy-duty
relays used to control starters and other industrial components. Although they are more
expensive than general purpose relays, they are generally more durable. The biggest
advantage of machine control relays over general purpose relays is the expandable
functionality of Machine Control Relays by the adding of accessories. A wide selection
of accessories is available for machine control relays, including additional poles,
convertible contacts, transient suppression of electrical noise, latching control and
timing attachments.
Reed Relays are a small, compact, fast operating switch design with one contact, which
is NO. Reed Relays are hermetically sealed in a glass envelope, which makes the
contacts unaffected by contaminants, fumes or humidity, allows reliable witching, and
gives contacts a higher life expectancy. The ends of the contact, which are often plated
with gold or another low resistance material to increase conductivity, are drawn
together and closed by a magnet. Reed relays are capable of switching industrial
components such as solenoids, contactors and starter motors. Reed relays consists of
two reeds. When a magnetic force is applied, such as an electromagnet or coil, it sets up
a magnetic field in which the end of the reeds assume opposite polarity. When the

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magnetic field is strong enough, the attracting force of the opposite poles overcomes the
stiffness of the reeds and draws them together. When the magnetic force is removed,
the reeds spring back to their original, open position. These relays work very quickly
because of the short distance between the reeds.
Solid state relays consist of an input circuit, a control circuit and an output circuit.
The Input Circuit is the portion of a relays frame to which the control component is
connected. The input circuit performs the same function as the coil of
electromechanical relays. The circuit is activated when a voltage higher than the relays
specified Pickup Voltage is applied to the relays input. The input circuit is deactivated
when the voltage applied is less than the specified minimum Dropout voltage of the
relay. The voltage range of 3 VDC to 32 VDC, commonly used with most solid-state
relays, makes it useful for most electronic circuits. The Control Circuit is the part of the
relay that determines when the output component is energized or de-energized. The
control circuit functions as the coupling between the input and output circuits. In
electromechanical relays, the coil accomplishes this function. A relays Output Circuit is
the portion of the relay that switches on the load and performs the same function as the
mechanical contacts of electromechanical relays. Solid-state relays, however, normally
have only one output contact.
3.7.4 Advantages
 They are quick acting and can be reset fast.
 They are simple in construction.
 They are reliable.
 The values can be easily set. No special programming device is required.
 People can be trained on these relays easily

3.7.5 Disadvantages
 The VA burden of these relays is higher than static and numerical
relays. Hence, the Potential and the Current Transformers should have a higher
capacity.
 These relays require to be calibrated periodically and tested.
 These relays suffer from the effects of age. As time passes, the springs and the
linkages inside the relay grow weak. This causes the setting values to
drift. This can result in maloperation and false trips.

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  These relays do not have the directional feature.
 The speed of operation is limited by the mechanical inertia of the moving
components.
 Multifunctioning is not possible. One relay can perform only one function.

3.8 DC Motor
DC motors are motion components that take electrical power in the form of direct
current (or some manipulated form of direct current) and convert it into mechanical
rotation. The motors do this through the use of magnetic fields that arise from the
electric currents to spur rotation of a rotor fixed with an output shaft. Output torque and
speed depends on the electrical input and motor design. In this project DC motors were
used run the conveyor belt and the packaging unit. When the system gets power from
the power supply the DC motor which is connected to the conveyor belt, starts rotating
and that’s how the whole process gets started. A DC motor is shown in Fig. 3.8 shows
a DC motor.

Fig. 3.8 DC Motor [21]

3.8.1 Principle
This DC or direct current motor works on the principal, when a current carrying
conductor is placed in a magnetic field, it experiences a torque and has a tendency to
move. This is known as motoring action. If the direction of current in the wire is
reversed, the direction of rotation also reverses. When magnetic field and electric field
interact they produce a mechanical force, and based on that the working principle of DC
motor is established.

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3.9 DC Power supply
DC power supplies are power supplies which produce an output DC voltage. Power
supplies are devices that deliver electric power to one or several loads. They generate
the output power by converting an input signal into an output signal (in this case, a DC
output). A DC power supply is shown in Fig. 3.9

Fig. 3.9 DC Power supply [22]

3.10 DM8 230R

A lot of variety of expansion module is available for logo PLC. This expansion
modules enable the user to add required extra input/output port. DM8 230R has 4/8
inputs with same number of outputs. Its supply voltage is 115 – 230 V AC/DC. For its
short circuit protection external fuse is required. This module is used with Siemens
Logo PLC in this project to add more outputs required.
3.10.1 Advantages
 Provides extra input
 Provides extra output
 Works with AC supply

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 Table 3.2 Specification of DM8 230R [10]

LOGO! DM8 230R

Inputs 4/8
Input / supply voltage 115...230 V AC/DC
Permitted range 85 V AC to 265 V AC
100 V DC to 253 V DC
with signal “0” max. 40 V AC
with signal “1” min. 79 V AC
Input current 0.08 mA AC
0.13 mA DC
Outputs 4 / 8; relays
Continuous current 5 A with resistive load;
3 A with inductive load
Short-circuit protection External fuse required
Switching frequency 2 Hz with resistive load;
0.5 Hz with inductive load
Power loss 1.1...3.3 W at 115 V AC
2.4...4.8 W at 240 V AC
0.5...1.8 W at 115 V DC
1.2...2.4 W at 240 V DC
1.1...4.5 W at 115 V AC
2.4...5.5 W at 240 V AC
0.6...2.9 W at 115 V DC
1.2...4.8 W at 240 V DC
Dimensions (W x H x D) 35.5 (2 MW) x 90 x 58 mm /
71.5 (4 MW) x 90 x 60 mm
Article No. 6ED1055-1FB00-0BA2 /
6ED1055-1FB10-0BA2

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3.11 Functional Block Diagram of the Project
Initial functional block diagram is shown in Fig. 3.1. In this diagram the operational
procedure of this project is shown. At the beginning of the operation photo sensor 1
detects the product. When the product is detected by the sensor 1 the motor 1 starts
rotating and moves the product with the robotic arm. Robotic arm pushes the product
forward to the packaging platform. On its way photo sensor 2 detects the product and
relay this information. When photo sensor 2 detects the product the stamping unit gets
activated and prints the necessary information on the product. After finishing the
stamping process the arm starts pushing the product forward again and places the
product on the packaging platform. After receiving each product the platform rotates 90
degree on its axis vertically. A proximity sensor controls the accuracy of the rotation of
the platform. After receiving 4 consecutive products the platform gives a rotation about
360 degrees on its axis. In this way four products get palletized. The entire process is
controlled by a single PLC. The programming of the PLC is done using Ladder
Diagram (LD).

Fig. 3.10 Functional block diagram of an automatic packaging machine

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3.12 Circuit Diagram
Fig. 3.10 shows the circuit diagram of the PLC based packaging machine.

Fig. 3.11 Circuit Diagram of PLC – based Packaging and stamping machine
In the diagram shown above a Logo PLC and an extension module DM8 230R are
connected together. The logo PLC has 8 input and 4 output [11]. In the above circuit
diagram 6 inputs from the mentioned 8 input is used. All the 4 outputs were a used and
an additional output from the DM8 230R module was also used. Here the details of the
input and output are given –
 I1 – Photo Sensor 1
 I2 – Photo Sensor 2
 I4 – Proximity Sensor
 I6 – Limit Switch 1

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  I7 – Limit Switch 2
 I8 – Start/Stop

I3 and I5 remain unused.

 Q1 – R1 (Relay 1)
 Q2 – R2 (Relay 2)
 Q3 – R3 (Relay 3)
 Q4 – R4 (Relay 4)
 Q1 (DM8 230R module) – Rotation of the packaging Platform

3.13 Flow Chart

Fig. 3.12 Design flow of this project

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In the above design flow of this project, the operation of this project is shown step by
step. For every input the corresponding output and the sequence of operation are also
shown.
3.14 Hardware Implementation
In this section the complete implementation of the practical interfacing will be shown
step by step with proper demonstration.
3.15 Packaging Machine Structure
The base of the machine is divided into two parts. The base of the both parts is made of
thin wooden board the upper platform including the packaging platform is made by
plastic sheets. Both of the arm to move the product and to print the date is made by
aluminium panel.
3.16 Loading the Program into PLC
The program which was done by LD has to be loaded into the PLC using the PLC
cable. This cable links the PC with PLC. After the completion of the loading of the
program a confirmation message will be shown the PC screen. After the confirmation,
PLC is ready for operation.

3.17 Working of the Entire System

After connecting the power supplies two the AC power source, the system gets
activated by pressing the push button. When button is pressed the proximity sensor
automatically adjust the position of the packaging platform. When sensor 1 detects the
product the robotic arm gets activated and pushes the box forward. On the way, when
sensor 2 detects the box again another arm prints the required information on the box.
The first arm remain standstill at this instant. Then again it pushes the product forward
to the packaging platform. When the platform is filled with 4 boxes, it palletizes all of
them together. By this time the robotic arm returns to its initial position automatically
and waits for the next operations.
3.18 Software Used
To program the PLC Logo Soft Comfort software is used in this project. Ladder
Diagram (LD) method is used as a programming language.

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3.19 Ladder Diagram

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28
Fig. 3.13 Ladder Diagram of this Project

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 Chapter 4
Result and Discussion
4.1 Introduction
In this chapter the performance of automatic packaging machine is discussed. This
project worked perfectly during experimental operation. The sensors used in this project
accurately sensed the movement of the product. The automatic packaging machine
worked smoothly according to the procedure.
4.2 Sensor Performance
In this project sensors played a key role. Here proximity, limit switch and photo sensor
were used for sensing purpose. Photo sensor detected the movement of the product
perfectly. Limit switch controlled the movement of the robotic arms. Proximity switch
perfectly positioned the rotating platform.
4.3 Overall Performance
The overall performance of the packaging machine was satisfactory but there some
improvement is needed on the palletizing section. The machine’s operation time was
fast enough and it has enough accuracy as a packaging machine.

Fig. 4.1 Packaging Machine Setup

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4.4 Cost Analysis
Table 4.1 Cost Analysis
Equipment Price (BDT)
Siemens Logo PLC 8000
DC Motor 200
Gear Motor 300
Limit Switch 200
Photo Sensor 2000
Power Supply 800
Relay 100
Others 2000
Total 13700

4.5 Advantages
 Vertical product transportation is possible.
 Problems with conveyor belt system like belt cleaning, jamming etc. are
avoided.
 Product’s weight has less effect on the system
 Product’s shape has a little or no impact on the operation
4.6 Limitations
 Higher initial cost.
 Regular maintenance required.
 Precise calibration is needed otherwise perfect operation won’t be possible.
 Sensors must be placed at an accurate place.
4.7 Application
 It can be used in food factories.
 It can be used in small parts manufacturing industries where quantitive packaging is
required.
 Industries which requires vertical product transportation can apply this system.
4.8 Discussion
In this project, PLC based automatic stamping and packaging machine was designed
and implemented. Though there some slight problems are observed in the operation but

31
it was quite effective, accurate and fast enough. The problem with the alignment of the
packaging platform can be solved by remaking the platform in precise shape and
measurement.

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 Chapter 5
Conclusion
5.1 Conclusion
The technology of automation is developing rapidly at present. The necessity of more
fast and accurate machinery such as automatic packaging machinery is increasing day
by day. This type of automatic packaging machine reduces the human labor, operational
cost and increases the accuracy of overall operation. This machine employs robotic arm
instead of conveyor belt. Therefore it can transport all types of product at any
environment. It also avoids the jamming problem of the conveyor belt system. It also
enables the user to do the vertical transportation.

5.6 Future Improvement

There’s a lot of scope of improvement in this project. Every day the field of automation
is developing. This system can be further developed by eliminating the problem of the
calibration. This can be made more fast and accurate by employing more advance
robotic arm.

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