1

CHAPTER 1

INTRODUCTION

1.1. CASE PACKER

Case packer is an automatic end-of-the-line packaging machinery capable

of packing food beverages, oil cans, flour packs etc., The rate of production of an
industry heavily depends on its packaging capability. Thus case packer assumes
chief importance in the production lane and it needs to be fast enough to
accomplish required production rate.

The case packer has a completely automated mechanism to aid the

packaging of food products, oil cans, other packets etc., This has a single lane
diverted to multi lane capability, pneumatic cylinders to open and close the carton
box during packaging. Also, the case packer must have some additional features
like provision for stopping and moving conveyor on arrival of empty carton boxes
for packing. This must also aid the boxes to be sealed at the end of packaging
operations.

1.1.1. Product Variety

Conventional case packers use pneumatic actuation for sequencing the

products. This provokes some delay in the packaging operation because of its
inherent nature of slow and smooth actuation. This pneumatic system accounts
for one of the major cause for delay in production line. While aiming at increasing
the speed of end-of-the-line packaging system, we have to consider modification
of prevailing pneumatic system to achieve faster production line.

In addition to the delay in existing system, the conventional machines lack

in product variety. This means that a conventional case packer machine can only
operate for a particular variety of product and it cannot accommodate any product
size variations. Thus, a conventional case packer machine has to be mechanically
configured to aid the product variation. This is one of the major drawback in the
existing system.
 2

1.1.2. Product Change Over Capability

The product change over capability of a case packer heavily relies on its
mode of automation. The machine with which product change over is capable with
less human intervention is highly desirable in the modern end-of-the-line
packaging system. Also, incorporating such feature will reduce the operator’s
effort to configure the machine. But, the cost for initial investment made on
fabricating such a machine will be considerably high than that of conventional
machines. But, as the operating cost reduces as a result of reduced human
intervention, the advantages of the system overweigh the initial investment made.

1.1.3. Type of Loading

In some of the packaging system, side loading and bottom loading are
widely used. This also accounts for the delay in the end-of-the-line packaging
system. The side loading and bottom loading has to be replaced by top loading in
order to increase the speed of operation. The top loading operation can be
effectively performed by the pick and place operation rather than the conventional
one. With its inherent ability to operate with greater speed of operation and
precise loading, pick and place systems are highly desirable.

1.1.4. Multi Layer Packing

Multi layer packing provokes a need for using precise loading operation to
prevent any glitches in the packaging operation. In this packaging operation, a
corrugated case has to be filled with two or more layers of products within the
same case. While doing such operation, it is desirable to provide some means of
layer separation by inserting a sheet of carton in between the two layers.

In addition to that product change over operation sometimes provokes a

need to modify the matrix dimensions of the case packing operation. This can be
managed well by automating the machine using programmable logic controller
device coded for such flexibility. As Programmable Logic Controllers has inherent
ability to adapt for the change in operation, it can be easily programmed to make
flexible changes in the matrix dimension.
 3

1.1.5. Changes in Matrix Dimension

The case packer machine has to incorporate all these modern features to
aid faster end-of-the-line packaging applications. Servo control operation can be
used to replace the conventional pneumatic actuation. By using servo control, we
can ensure auto indexing of corrugated boxes and also we can increase the
speed of operation considerably.

The variation in the matrix dimension of the packaging operation can be

easily carried out by providing flexible programmable logic controller program.
Based on the input given at the human machine interface, we can easily
accomplish the variation in matrix dimension during case packing operation.

Product change over capability can be incorporated into the case packer
machine by suitable programmable logic controller programming of lane diverter.
This can aid the case packer machine to configure to the varying product
dimensions with less human intervention.

Thus this project is better suited for versatile machines, which have to be
operated under various configurations. The servo control aided with PLC
programming ensures faster changeover time with less human intervention. Also,
this is a viable project which can increase its production rate compared to that of a
pneumatic operated machine, by reducing the glitches in actuation mechanisms.

1.2. NEED FOR AUTOMATION

In order to accomplish increased speed of operation and enhanced product
change over capability, the case packer machine has to be completely automated.
Thus, automation of conveyor mechanism, lane diverter, case sealer etc., has to
be done with extreme care so as to increase the speed of operation and also to
enhance the flexibility of the system.
The automation of the case packer machine can be done through several
ways. Of them, automation by using PLC is widely used in the industries, because
of its ease of automation and comparatively less cost for automating the system.
 4

This project work mainly focuses on automating the lane diverter in the
case packer machine using RS Logix software and by using Micrologix hardware
to accomplish the automation of the case packer machine. The lane diverter
automation aids the complete system to increase its speed because of its ability
divert the product to the required number of lanes.
The lane diverter can also be incorporated with certain features like aiding
faster product change over capability, thus reducing the human efforts needed to
make changes in machine configuration while it is required to be changed on
facing other product variety of its kind. Thus the automation of lane diverter
mechanism in the pick and place case packer can considerably increase the
speed of operation and also has the ability to provide faster product change over
capability and thus enhance the flexibility of the system.

1.3. OBJECTIVE
The main aim of this project is to increase the production rate of a
manufacturing industry by modifying the end-of-the line packaging system. This
can be accompanied by altering the lane diverter unit in the pick and place case
packer machine. This can be done by determining the parameters to be controlled
on the lane diverter and programming the complete machine with suitable
Programmable Logic Controller.
 5

CHAPTER 2

LITERATURE REVIEW

Most of the previous case packer automation works were concentrated

mainly on reducing the flaws in pneumatic setup in order to increase the
packaging operation. The case packers are mainly treated with pneumatic
actuation rather than of any other electrical actuation methodologies. Pneumatic
actuation is time consuming and very difficult to adopt for different product
varieties. In this project work, introduction of servo control in place of pneumatic
actuation is done.

1.) Jim Beam (2002) presented a paper on ‘Advanced Case Packers to Protect
Bottles and Increase Efficiency’ in the FlexLink industrial journal. This work mainly
concentrated on introducing safe and reliable case packing system and to have
faster case packing operation. This paper presents key concepts on increasing
the operational speed by introducing alternative source of actuation and discusses
the advantages and disadvantages of various options available for the packaging
operation. One of the widely explained concepts is the replacement of pneumatic
system with the hydraulic system but this provides certain limitations to the safety
and speed of case packing operation. This work shows that the various case
packing operations can be accomplished at various speed but the appropriate
kind of case packing relies on the product to be handled. This work also
emphasize on the appropriate selection of case packer according to the product
varieties to be handled and to enhance the flexibility of the case packer system.
From this work, various advancements in the case packing machinery to handle
variety of bottle packing methodologies were understood.

2.) George Miltan (2004) had made a relevant work on the ‘Tandem Servo
Case Packers to Handle a Variety of Bottle Shapes and Materials with Ease of
Operation’. In this work, he stated various options available for the case packing
operation and this especially deals with the handling of various bottle shapes in a
single machine. Several analysis have been made on flexibility of the system and
 6

various options available were examined for their compatibility to handle variation
in product shapes and sizes.

3.) M.Nakamura and S.Goto (2002), analysed various options available for the
servo controlled case packing operation and published their work in the title
‘Mechatronic Servo System Control’. This work mainly emphasizes on the
effective designing of the lane diverter and deals with the appropriate usage of
servo control mechanisms to avail flexibility of the system. The servo control unit
has an inbuilt encoder which is capable of auto indexing. The auto indexing
feature enables the case packer machine to have increased operational speed
because of its ease of availing feedback signals about the various positions of the
corrugated case available in the conveyor unit. The servo control has been widely
suggested because of its wide power range and its integrity with various electric
drives. The servo control provides feedback signal by either position control or
contour control. The position control emphasizes the arriving time and stop
position from any point without considering the response route. The contour
control emphasizes on the motion trajectory from the current position. Hence, in
this kind of contour control, the position at each moment and its motion velocity
were keenly observed to provide the feedback signal.

4.) FlexLink Standard Solution Company (2007) analysed various lane diverter
operations available in case of case packing operation. The bottle case packing
can be dealt by horizontal diverter with multi lane diverting operation. This is
because case packing of bottles cannot be carried out with vertical case packer
and bottle case packing will not be effective with side loading operations. These
things are taken into consideration before going for the design of case packer
machines. Also the case packing operation for bottles or cans is effective by using
pick and place robots for bottle handling. Because the case packer can provide
safe and reliable bottle handling by using a pick and place robot than the
conventional case packer operation.
 7

2.2. SUMMARY

From this literature survey, various advancements in the field of case

packing were understood. Also, it is observed that the case packing
operation for bottles and cans require special attention while packing. The
factors governing the speed of case packing operation were studied in
detail and ways to improve the case packing efficiency were observed. The
use of servo control in the case packing operation and its ability to provide
precise position control of carton boxes were examined. This learning was
used in the enhancement in speed and operational efficiency of case
packing machine and the automation of the lane diverter unit.
 8

CHAPTER 3

PROBLEM ANALYSIS

3.1. PROBLEM ANALYSIS

In the end-of-line packaging, the speed of operation is the major factor of

the production rate. In conventional case packer machine, the speed of operation
is restricted by the pneumatic actuators. Hence, an advanced packaging system
with high speed of operation is required. This provokes the need to modify the
existing case packer machine with improved control capabilities.

3.1.1. Problem Identification

In modern packaging systems, several efforts have been taken to tackle

the lower packaging rate problem. Here, several techniques were suggested to
improve the factors governing positioning of carton boxes and auto-indexing. Of
them servo-controlled indexing and pick-and-place operation were of higher
merits.

3.1.2. Problem Solution

Acceleration of packaging operation can be executed by eliminating the

use of pneumatic actuation. This can be replaced by a servo control system. This
servo control system can be used along with the lane diverter unit to aid the
speed of operation. The lane diverter unit must also be automated with a suitable
Programmable Logic Controller unit

3.1.3. Advantages

 Servo control can save time and money throughout the machine lifecycle
from design and installation through operation and maintenance.
 The servo drives can meet the needs of almost any machine, with complete
power coverage up to 150 kW.
 Compatible status codes, I/O, feedback cables and safety connections.
 One drive solution for permanent magnet (synchronous) and induction
(asynchronous) motors.
 9

3.2. FEASIBILITY STUDY

3.2.1. Economic Feasibility

This system can be implemented easily because of its ease of automation

and ability to reduce packaging time and precise operation. The only concern is that
initial cost of investment is little bit higher than the conventional one. But its’
advantages overweigh the initial investment.

3.2.2. Operational Feasibility

It is easy to operate. Also the product change over time is less and this can
be done with relatively small human intervention. Because, the system is
programmed in such a manner that the product change over can be easily carried
out by single push operation and hence avoid time consuming labour effort.

3.2.3. Technical Feasibility

In Software side we used PLC programming tool called RS Logix 500

series which will compile the ladder logic program with better user interface. In the
hardware side, Micrologix 1400A PLC instrument is needed to facilitate the
programmed operation to be carried out.
 10

CHAPTER 4

FACTORS CONSIDERED ON SELECTING A CASE PACKER

The need for a new packer may simply be to replace an aging, high
maintenance machine, or it may be driven by new packages, higher line speeds,
efficiency initiatives, or new packaging requirements. The following factors provide
some basic considerations that can be used in the process of selecting a case
packer.

4.1. TYPE OF CASE

The starting point for determining the optimal case packer is to identify the
type of case for the packaging application. Few case types are as follows:
1) top load RSC (regular slotted container);
2) side load RSC or end load RSC;
3) wraparound.
For example, liquor stores strongly prefer RSC top load cases over
wraparound, as the RSC case has utility for customers who buy several bottles.
Top load RSC cases offer the best stacking strength and are ideal for
compressible products such as pouches, large PET bottles, personal care and
trigger bottles. Top load cases also allow for partitions to increase stacking
strength or to minimize bottle to bottle contact.

4.2. PRIMARY PRODUCT

The type of container (or primary product) will often influence the packer
type. Expensive beverages such as top shelf spirits require a partitioned case,
which will usually dictate a drop packer or soft placement packer. Side load case
packers are often used for boxed items like dry pasta or bars of soap because
pushing the product from the side is easier then top loading. For the larger
products such as outdoor grills, bottom load packers are most gentle on the
primary product, as the case is pushed over the product.
 11

4.3. LINE SPEEDS

The rate of the line, as dictated by the upstream filling or processing is a

key factor when selecting the correct packer. Selecting a packer with enough
speed is important, however too much speed may be an unnecessary cost.
Generally speaking, speeds below 20 cases per minute can be done effectively
with side load packers, bottom load or robotic packers. For speeds from 20 to 35
cases per minute, drop packers or intermittent motion wraparound packers are
good choices.

Soft placement packers, servo drop packers, rotary packers, and

continuous motion wraparound packers are able to handle speeds above 35
cases per minute. Carefully consider a packers infeed and laning technology, as
this becomes critical at higher speeds.

4.4. MACHINE LOAD

It is essential when selecting a case packer to ensure that it is designed

for the job and the best way to determine this is to see one running a similar
application. Consider factors such as weight of the product being handled, true
production rates, and runtime per week. If the machine has to meet a high
production demand, we have to build a robust solution and although the initial cost
may be higher, the reduced life cycle costs will justify the initial investment.

4.5. FLOOR SPACE

Plant floor space is a premium and some solutions can take up more
space than others. Intermittent motion wraparounds are usually space efficient
versus alternatives; however continuous motion wraparounds are usually very
wide and long. Drop packers and soft placement packers offer narrow profiles with
flexible layouts (inline, counter-flow, or right angle). Although robots can be space
efficient, consider the guarding requirements in the layout.
 12

4.6. CHANGEOVER AND FLEXIBILITY

In this area, all machines are not created equal. Robotic Packers are
best in this category with quick changeovers. Some can even be partially
automated. Drop Packers come in second and have the benefit of easy and
simple changeover. Rotary packers and soft placement packers fall somewhere in
the middle, as there are more change parts to handle. Wraparound packers are
usually the least flexible, in particular for new packages that are added in the
aftermarket.

We have to consider all these factors while selecting a case packer. Thus
the main objective in selecting a case packer relies on getting good line
efficiencies and low life cycle costs with the available initial investments.
 13

CHAPTER 5

DESIGN AND DESCRIPTION

5.1. SERVO CONTROL

5.1.1. Introduction

Servo is a term which applies to a function or a task in which a command

signal which is issued from the user's interface panel comes into the servo's
"positioning controller". The positioning controller is the device which stores
information about various jobs or tasks. It has been programmed to activate the
motor/load, i.e. change speed/position.
The signal then passes into the servo control or "amplifier" section. The
servo control takes this low power level signal and increases, or amplifies, the
power up to appropriate levels to actually result in movement of the servo motor.
These low power level signals must be amplified: Higher voltage levels are
needed to rotate the servo motor at appropriate higher speeds and higher current
levels are required to provide torque to move heavier loads.

Figure 5.1. SERVO CONTROL

 14

This power is supplied to the servo control (amplifier) from the "power
supply" which simply converts AC power into the required DC level. It also
supplies any low level voltage required for operation of integrated circuits.
As power is applied onto the servo motor, the load begins to move & speed
and position changes. As the load moves, so does some other "device" move.
This other "device" is either a tachometer, resolver or encoder (providing a signal
which is "sent back" to the controller). This "feedback" signal is informing the
positioning controller.
The positioning controller looks at this feedback signal and determines if
the load is being moved properly by the servo motor; and, if not, then the
controller makes appropriate corrections. For example, assume the command
signal was to drive the load at 1000 rpm. For some reason it is actually rotating at
900 rpm. The feedback signal will inform the controller that the speed is 900 rpm.
The controller then compares the command signal (desired speed) of 1000 rpm
and the feedback signal (actual speed) of 900 rpm and notes an error. The
controller then outputs a signal to apply more voltage onto the servo motor to
increase speed until the feedback signal equals the command signal, i.e. there is
no error.
Therefore, a servo involves several devices. It is a system of devices for
controlling some item (load). The item (load) which is controlled (regulated) can be
controlled in any manner, i.e. position, direction, speed. The speed or position is
controlled in relation to a reference (command signal) as long as the proper
feedback device (error detection device) is used. The feedback and command
signals are compared, and the corrections made. Thus, the definition of a servo
system is, that it consists of several devices which control or regulate
speed/position of a load.

5.1.2. Working of Servo Control

The control wire is used to communicate the angle. The angle is

determined by the duration of a pulse that is applied to the control wire. This is
called Pulse Coded Modulation. The servo expects to see a pulse every 20
milliseconds (.02 seconds). The length of the pulse will determine how far the
 15

motor turns. A 1.5 millisecond pulse, for example, will make the motor turn to the
90 degree position (often called the neutral position). If the pulse is shorter than
1.5 ms, then the motor will turn the shaft to closer to 0 degress. If the pulse is
longer than 1.5ms, the shaft turns closer to 180 degress.

Figure 5.2. SERVO CONTROL OPERATION

As you can see in the picture, the duration of the pulse dictates the angle of
the output shaft (shown as the circle with the arrow). Note that the times here are
illustrative, and the actual timings depend on the motor manufacturer. The
principle, however, is the same.

5.1.3. Characteristic of Servo System Applications

The emergence and structure of mechatronics have been briefly introduced
in the former part. In order to understand that the usage of this mechatronic servo
system is different from the general servo system, the main points are listed as
below:
 16

1.) In a mechatronic servo system, there are two types of control.

a) One is position control (PTP: point to point) emphasizing the arriving time
and stop position from any position without considering the response route.
b) Another is the contour control (contouring or CP: continuous path)
emphasizing the motion trajectory from the current position to the next
position (position at each moment and its motion velocity).
The former one is the robot arm for element assembly, spot welding, etc, or
used for the control of moving axis of mechanism for drilling a hole. The latter one
is the arm of welding robot, painting robot, laser cutting robot, etc, or used for the
control of transfer axis of mechanism implementing any three-dimensional shape
processing (machine center, etc).
2.) In the contour control, an overshoot in the position control system should not
occur. In many cases, velocity control system is also regulated so that the
overshoot cannot occur. In the various kinds of actual processes, the generation
of overshoot of position will cause fatal defect of shape. For example, in the
process of constructing a shaft, if an overshoot occurs, the radius of the part
becomes smaller, reducing the strength of this part. Moreover, if the vibrated
trajectory exists insufficiency of shape, it cannot be revised at the later motion.

5.1.4. Advantages of Servo Control:

 Integrated Motion — Servo control can save time and money throughout
the machine lifecycle from design and installation through operation and
maintenance.
 Quality — Outstanding performance is based on established, successful
product designs.
 Power range and scalability — The servo drives can meet the needs of
almost any machine, with complete power coverage up to 150 kW. Thus
we can take the advantage of a single solution to meet all our needs.
 Common User Experience — Compatible status codes, I/O, feedback
cables and safety connections.
 Motor flexibility — One drive solution for permanent magnet
(synchronous) and induction (asynchronous) motors.
 17

5.2. CASE PACKER

5.2.1. Case Packer Specification

Table 5.1. CASE PACKER – SPECIFICATION

Speed: Up to 50 lube canes (1.5 l)

Versatile packer handles all sizes within the lube oil canes
Product Sizes:
ranging from 1.5l to 10l.
Machine Heavy-duty stainless steel, tubular with weldments.
Construction:
Case Types: Plastic, corrugated, HSC, RSC, Tablock, tray

Air: 80 psi with 1/2" NPT

Product Infeed: 1 HP with variable frequency drive
Casefeed: 1 HP with variable frequency drive
Motors:
Case Timing: Servo drive
Lift Table: Servo drive

Controls: I/O devices, 24 Volts, Contrologix or other upon request

Mounted to machine opposite operator side; one connection
Main Control Panel:
at 30 Amp, 460 Volts

Enclosures: NEMA 12, NEMA 4 or NEMA 4X

Operator Interface: Panelview or others

Servo System: Rockwell Contrologix, or other upon request

5.2.2. Special Features

1. Product infeed with optional zero-gap bottle laner

2. Simple drop-in lane spacers
3. By-the-numbers changeover system
4. Fully-interlocked Lexan guards
5. Swivel-mounted operator interface
6. Robust stainless steel construction
7. Servo Axis I for vertical motion of table ("soft catch").
8. Flap opener for reshipper cases
 18

5.3. LANE DIVERTER

The lane diverter takes a single lane of multi-ribbon lube oil cans and
diverts them into three lanes. The speed of the servo controlled lane diverter is
adjustable to receive a continuous flow of properly spaced product at a maximum
rate of sixty 12” long loaves per minute, or sixty-eight 10.5” long loaves per
minute. Groups of sliding platens form under each loaf as it passes from the
upstream conveyor and onto the lane diverter.

Figure 5.3. SEQUENCE OF LANE DIVERTER OPERATIONS

Lube oil cans are directed to either the left or right lane depending on
downstream demand. Two urethane belt conveyors include small diameter infeed
and exit pulleys for smooth transfer of loaves into and out of the lane diverter.
Product is diverted 3” in each direction and exits the lane diverter on a
centerline spacing of 6”. The lane diverter is built to USDA dairy guidelines and
features stainless steel construction. The robust cantilevered conveyor design is
sanitary and easy to clean and maintain.
 19

Figure 5.4. SERVO CONTROLLED LANE DIVERTER

 20

5.4. ROW PUSHER

Each section of a case packer machine deposits finished bottles on a dead

plate and a pushout mechanism displaces the bottles from the dead plate through
an angle of about from 90° to 120° onto a moving conveyor. Such pushouts have
a set program of displacement with the pusher fingers of the mechanism.

First being axially advanced to the dead plate to receive the formed bottles
and following a short period of time during which the bottles settle down, then
rotated through a circular arc to deposit the bottles on the conveyor. The pusher
fingers are then axially retracted leaving the bottles on the conveyor and rotated
back to their initial position.

As case packer machines increase in speed conveyor capacity must be

increased and this is normally achieved by speeding up the conveyor. This is
undesirable since bottle control lessens as conveyor speed increases.

It is accordingly an object of the present invention to increase the capacity

of the conveyor without suffering a loss in bottle control.

Other objects and advantages of the present invention will become

apparent from the following portion of this specification and from the
accompanying drawings which illustrates in accordance with the mandate of the
patent statutes a presently preferred embodiment incorporating the principles of
the invention.
 21

Figure 5.5. SERVO CONTROLLED ROW PUSHER

 22

5.5. PICK AND PLACE ROBOT

Pick and place robot is an electric machine which has some ability to
interact with physical objects and to be given electronic programming to do a
specific task or to do a whole range of tasks or actions. It may also have some
ability to perceive and absorb data on physical objects, or on its local physical
environment, or to process data, or to respond to various stimuli.
This is in contrast to a simple mechanical device such as a gear or
a hydraulic press or any other item which has no processing ability and which
does tasks through purely mechanical processes and motion.

Figure 5.6. PICK AND PLACE ROBOT CONTROL UNIT

Industrial robots usually consist of a jointed arm (multi-linked manipulator)

and end effector that is attached to a fixed surface. One of the most common type
of end effector is a gripper assembly.
Industrial robots are also used extensively for palletizing and packaging of
manufactured goods, for example for rapidly taking drink cartons from the end of a
conveyor belt and placing them into boxes, or for loading and unloading
machining centers.
 23

In recent years, robotic packaging systems have become more prevalent.

With the developments in technology and quality control, robot cells are showing
up in packaging applications everywhere. In fact, many manufacturing managers
see robot packaging as a necessity. Many companies are looking for ways to save
on systems.

Figure 5.7. PICK AND PLACE ROBOT

 24

5.5.2. Advantages

1) Speed - Robots work efficiently, without wasting movement or time.

Without breaks or hesitation, robots are able to alter productivity by
increasing throughput.
2) Flexibility - Packaging applications can vary. Robots are easily
reprogrammed. Changes in their end of arm tooling (EOAT) developments
and vision technology have expanded the application-specific abilities of
packaging robots.
3) Savings - Automated packaging minimizes costs across the board. Not
only is output increased, but robots are tireless. There are no labor
expenses with robot packaging.
 25

CHAPTER 6
PLC PROGRAMMING OF LANE DIVERTER

6.1. PLC SETUP - SPECIFICATION

The MicroLogix 1400 family provides small and economical programmable

controllers. They are available in configurations of 10 digital I/O (6 inputs and 4
outputs), 16 digital I/O (10 inputs and 6 outputs), 25 I/O (12 digital inputs, 4 analog
inputs, 8 digital outputs, and 1 analog output), or 32 digital I/O (20 inputs and 12
outputs) in multiple electrical configurations of digital I/O. The I/O options and
electrical configurations make them ideal for many applications.

6.2. BENEFITS

 Compact design of the MicroLogix 1400 controller can run well in limited
panel space.
 Choice of communication networks is more with MicroLogix 1400 series.
An RS-232-C communication port is configurable for direct connection to a
programming device or operator interface, DeviceNet networking,
EtherNet/IP networking.
 Simple programming with our choice of programming device afford us to
program these controllers in familiar ladder logic with MicroLogix 1400A,
RSLogix 500 Windows Programming Software, or the MicroLogix Hand-
Held Programmer. This symbolic programming language is based on relay
ladder wiring diagrams that simplify the creation and troubleshooting of
your control program.
 Comprehensive instruction set—Over 65 instructions including simple bit,
timer, and counter instructions, as well as instructions for powerful
applications like sequencers, high-speed counter, and shift registers.
 Execution time for a typical 500-instruction program is only 1.56 ms and
hence it is faster than any other medium sized programmable logic
controller device.
 26

6.3. DESCRIPTION

The PLC is used as a controller for the robotic arm movement. The limit
switches are connected to the input of the PLC. The solenoid valves are
connected to the output of the PLC. No analog value is present so there is no
need of analog module. The inputs connected in sourcing mode so that there will
not be nay mishap even in case of any fault. The sourcing mode is one in which
the negative supply is directly given to common and the Positive supply is
controlled by the limit switch. The output is also in sourcing mode i.e the negative
supply is given to the solenoid directly and the positive supply is controlled by the
PLC.

Table 6.1. PLC INPUT DESCRIPTION

Sl.No. Sensor Position Description Input

1 Push button Cycle start PB 1 I:0/0

2 Push button Cycle stop PB 2 I:0/1

3 Limit switch Drives ready LS 1 I:0/2

4 Limit Switch Matrix sensor 1 LS 2 I:0/13

Table 6.2. PLC OUTPUT DESCRIPTION

Sl.No. Actuator Movement Description Output

1 Solenoid valve 1 X axis SV 1 O:0/0

2 Solenoid valve 2 Z axis SV 2 O:0/1

3 Solenoid valve 3 Divider stop forward SV 3 O:3/8

4 Gripper Divider stop reverse SV 4 O:3/9

 27

6.4. I/O LISTING

Listing the input and output parameters in the PLC programming is very
vital for effective programming. The input parameters to be considered relies
heavily on the nature of the process and the output parameters to be controlled
mainly concerns with the kind of processing steps to be followed to achieve
effective packaging operation. While listing, proper care must be taken to account
the each and every devices to be controlled. This will ensure the better
programming of the machine.

Table 6.3. I/O LISTING

INPUT/ BIT
OUTPUT DESCRIPTION ADDRESS
I:0/0 CAR_STOP_UP_RS_LOAD_ i0
I:0/1 CAR_STOP_DN_RS_LOAD i1
I:0/2 DRIVES_READY1 i2
I:0/3 DIVERTER_HOME i3
I:0/5 CE_CAR_PRE_AT_FORM i4
I:0/6 CE_CAR_FORMED i5
I:0/7 GRIPPER_REV_RS i7
I:0/8 CAR_STOP_AT_LOAD_SEN i8
I:0/9 CAR_STOP_WAIT_1_SEN i9
I:0/10 AIR_PS1 i10
I:0/11 DOOR_OPEN1 i11
I:0/12 VERT_BRAKE_OK1 i12
I:0/13 MATRIX_SEN1 i13
I:0/14 HIGH_LEVEL_ACC_SEN i14
I:0/15 SLIP_PICK_FWD_RS i15
I:0/16 SLIP_PICK_REV_RS i16
I:0/17 SLIP_PLACE_FWD_RS i17
I:0/18 SLIP_PLACE_REV_RS i18
I:0/19 SLIP_INDEX_SEN i19
I:1/0 SUPPORT_CYL_REV_RS i6
I:1/1 OUTFEED_HIGH_LEVEL i32
I:1/2 MAJOR_FLAP_1_UP i33
I:1/3 MAJOR_FLAP1_DOWN_RS i34
I:1/4 MPCB_TRIP1 i35
I:1/5 START_PB i21
I:1/6 STOP_PB i22
I:1/7 RESET_PB i23
I:1/8 AUTO_MANUAL i24
 28

I:1/9 CONTROL_ON i25

I:1/10 CE_PICK_FWD_RS i26
I:1/11 CE_PICK_REV_RS i27
I:1/12 CE_OPEN_FWD_RS i28
I:1/13 CE_OPEN_REV_RS i29
I:1/14 MINOR_FLAP_UP_RS i30
I:1/15 MINOR_FLAP_DN_RS i31
I:1/1057 VERTICAL AXIS i40
I:1.69 Axis 1 - Feedback i41
I:1.70 Axis 1 - Feedback i42
I:1/1137 HORIZONTAL AXIS i43
I:1/1151 Axis 2 - Position i44
I:1.74 Axis 2 - Feedback i45
I:1.75 Axis 2 - Feedback i46
I:1.79 Axis 3 - Feedback i47
I:1.80 Axis 3 - Feedback i48
I:2/0 CARTON_FEED_FWD_RS i32
I:2/1 CARTON_FEED_REV_RS i33
I:2/2 CAR_TOP_GUIDE_FWD_RS i41
I:2/3 CAR_TOP_GUIDE_REV_RS i34
I:2/4 TAP_ENTR_GUIDE_UP_RS i35
I:2/5 TAPING_ENTRY_DN_RS i43
I:2/6 MAJOR_FLAP_2_UP_RS i36
I:2/7 MAJOR_FLAP_2_DN_RS i37
I:2/8 INDEX_SEN i44
I:2/9 CHAIN_CLEAT_LEFT_SEN i38
I:2/10 CHAIN_CLEAT_RIGH_SEN i39
I:2/11 CAR_PRESENT_AT_FEED i42
I:2/13 CARTON_AT_TAPING_POS i40
O:0/2 DRIVES_ENABLE1 o1
O:0/3 CAR_STOP_AT_LOAD_UP1 o2
O:0/4 CAR_STP_AT_LOAD_DN1 o3
O:0/5 MAJOR_FLAP_UP_BIT o4
O:0/6 MAJOR_FLAP_DN_BIT o5
O:0/7 CE_PICK_SUCTION_CUP o6
O:0/8 CARTON_CONVEYOR o13
O:0/9 MATRIX_CONVEYOR1 o9
O:0/10 IN_FEED_CONVYR1 o10
O:0/11 CAR_FORMING_SUCTION o11
O:1.0 Devicenet Command o12
O:1/0 Axis 1 - Pause Index o7
O:1/33 Axis 1 - Abort Index o8
O:1/44 Axis 1 - Start Index o16
O:1/57 Axis 1 - Reset o17
O:1/62 Axis 2 - Pause Index o14
 29

O:1/129 Axis 2 - Abort Index o15

O:1/153 Axis 2 - Reset o18
O:3/0 TAPING_ENT_GUIDE_UP o19
O:3/1 TAPING_ENT_GUIDE_DN o20
O:3/2 MAJOR_FLAP2_UP o21
O:3/3 MAJOR_FLAP_2_DOWN o22
O:3/4 CE_SIDE_DRIVE_LEFT o23
O:3/5 CE_SIDE_DRIVE_RIGHT o24
O:3/6 SIDE_DRIVE_LEFT o36
O:3/7 SIDE_DRIVE_RIGHT o37
O:3/8 DIV_STOP_FWD o25
O:3/9 DIV_STOP_REV o26
O:3/10 GRIPPER_FWD o27
O:3/11 GRIPPER_REV o28
O:3/12 SLIP_SUCTION_CUP o29
O:3/13 SLIP_PICK_FWD o30
O:3/14 SLIP_PICK_REV o31
O:3/15 SLIP_PLACE_FWD o32
O:4/0 SLIP_PLACE_REV o33
O:4/1 SLIP_INDEX_FWD o34
O:4/2 SLIP_INDEX_REV o35
O:4/3 RED o38
O:4/4 YELLOW o39
O:4/5 GREEN o40
O:4/6 CE_PICK_FWD o47
O:4/7 CE_PICK_REV o48
O:4/8 CE_OPEN_FWD o49
O:4/9 CE_OPEN_REV o50
O:4/10 MINOR_FLAP_FWD o41
O:4/11 MINOR_FLAP_REV o42
O:4/12 CARTON_FEED_FWD o43
O:4/13 CARTON_FEED_REV o44
O:4/14 CARTON_TOP_GUIDE_FWD o45
O:4/15 CARTON_TOP_GUIDE_REV o46
 30

CHAPTER 7

RESULTS AND DISCUSSION

The entire lane diverter unit in the case packer machine was automated
with the help of MicroLogix 1400 series device programmed with RS Logix 500
software. The process has been tested for increased speed and results were
tabulated in the table 7.1

Table 7.1. Results obtained after automating the lane diverter

PARAMETER BEFORE AUTOMATION AFTER AUTOMATION

Speed of operation 100 cans/minute 150 cans/minute

(1.5 litre cans)

Speed of operation 40 cans/minute 70 cans/minute

(5 litre cans)

Product change over time 25 minutes 10 minutes

From the above table, we can observe that the speed of operation is
considerably increased by the automation of pick and place case packer machine.
The replacement of conventional pneumatic actuation mechanism with the servo
control mechanism accounts for this considerable increase in the speed of
operation.

Also, it can be observed that the product change over capability has been
afforded with less human intervention. Requirement of less human labour force is
directly related with the product change over time. Thus speed of operation of the
pick and place case packer machine requires less than half of the time required in
the conventional case packer machine during its product change over period. This
shows that the fabricated model possess faster end-of-the-line packaging
operational speed and posses flexibility in the system according to the available
product variety.
 31

Figure 7.1. Fabricated Case Packer Machine

Figure 7.2. Fabricated Lane diverter unit

 32

CHAPTER 8
CONCLUSION

8.1. CONCLUSION

The PLC ladder logic program for the lane diverter was developed using
RS Logix 500 software. The system is programmed in such a manner that it will
provide flexible matrix dimension for packaging operation. After programming, the
lane diverter unit was tested for increased speed and product change over
capability. Results shows that introduction of servo control increases the speed of
case packer operation. The speed has been increased from 100 cans/minute to
150 cans/minute for a typical 1.5 Litre lube oil cans.
The product change over capability of the machine has been increased
with the automation of lane diverter in the case packing machine. Auto-indexing
facilitates easy positioning of corrugated boxes for packing and provide better
precision. Also the auto-indexing feature reduces the position timing of corrugated
boxes while packaging. The modification done in the conventional case packing
machine by automation of lane diverter machine can greatly afford increased
packaging speed and also provide flexibility to the case packing system.