2.5 High-Speed Discrete Control System Sponsored by Emerson Process Management Created by: Lacey Latour, Andrew Roessler and San Nguyen

Purpose Design a high-speed discrete control solution that could be used to demonstrate how Emerson could replace a programmable logic controller (PLC) with their DeltaV system. System Requirements: Discrete input to output in 5 – 50 ms The input is the switch to turn on the conveyor and the output is conveyor The sensor is read as a analog signal this is also high speed from the time the sensor reads the color till the actuator extends Must be movable and fit on a rolling cart. Must be controlled by a PLC. PLC must be replaceable by Emerson’s DeltaV system. Maintain a budget of $3,000 - $5,000.

Proposed Solution Design a sorting system operated by a programmable logic controller. System Hardware: (1) Conveyor Belt (1) Vibratory Feeder (1) Linear Actuators Colored Blocks Black and White (1) Color Sensor (1) Programmable Logic Controller: Allen Bradley Micrologix 1400

High-Level Design Blocks will be manually placed into the vibratory feeder’s tray. The color sensor will be placed towards the bottom of the feeder. When the blocks are fed, the color sensor will read each block’s corresponding color and relay this information to the PLC. If the block is white, the actuator will then extend and the block will follow the extension to the correct positioning on the conveyor If the block is black, it will stay In the same place on the conveyor Once the blocks have reached the end of the conveyor, they will then fall into their associated bin

Block Diagram Figure 1: High-Speed Discrete Control System Block Diagram

Bill of Materials Item Quantity Part Number Part Name Price Total Price 1 6C Drive Vibratory Feeder $360 2   2"x8" SS Tray $271 3 n12UN/115-2A-HW-NSF Control $288 4 HDA2-2 2.00" Stroke Linear Actuator $130 5 ROB-0953 Line Sensor Breakout $2.95 6 40-08048-R-D U4 RS-100N-20-31 Conveyor $1,553 7 30-7270 Electrical External Control Cable $26.20 8 30-7071 Stand $47.86 9 40-7031 Bracket $12.78 10 BLOCKS Wooden Blocks $10.00 Total Overall Price: $2,701.79

Hardware Specifications (1/5) Dorner 1100 Series Mini-Conveyor Purpose: means of moving each block from the vibratory feeder, through the linear actuators, then to each block’s color-respective bin. Purchased as a set including: Conveyor Extrusion Driver 15 ft. External control cable with option to enable I/O Features: Flat Belt End Drive Conveyor height: 1.50” Belt Width: 8” (203mm) Conveyor Lengths: 48” (1219mm) Loads up to 15 lbs. (6.8 kg) Voltage: 115 V 60 Hz Figure 2. Dorner 1100 Series Mini-Conveyor

Hardware Specifications (2/5) Eriez 6C Vibratory Feeder Purpose: Means of holding and supplying the blocks to the conveyor. Features: Feed Rate: 1250 lb./hr. Tray width: 1-1/2” Tray Length: 12” Overall height: 6-3/8” Voltage: 115V AC Amps: 1.1 Noise level: 70 dB 3600 Vibrations per minute Figure 3. Eriez 6C Vibratory Feeder

Hardware Specifications (3/5) Servocity HDA2-2 Linear Actuator Purpose: Means of pushing each block into its necessary position on the conveyor. Potentiometer wires will be responsible for positioning the blocks correctly on the conveyor belt. Features: Voltage: 6.0-12 Volts DC Operating speed (12V): 2.00” second at No load Operating Speed (12V): 1.37” second at Max load Dynamic thrust (12V): 25 lbs. thrust Connector wire length: 24" Figure 4. Servocity HDA2-2 Linear Actuator Figure 5. HDA2-2 Linear Actuator Wiring Diagram

Hardware Specifications (4/5) Sparkfun Electronics – Line Sensor Breakout (Analog) Purpose: Senses the color of the block that is fed from the vibratory feeder. Features: Analog output (varies depending on the amount of IR light reflected back to the sensor) Dimensions: 0.30 x 0.55 “ (7.62 x 13.97 mm) 5VDC operating voltage 25mA supply current Optimal sensing distance: 0.125" (3mm) Figure 5. Sparkfun Electronics Line Sensor Breakout

Hardware Specifications (5/5) Allen Bradley Micrologix 1400 Controller Purpose: Responsible for processing the color sensor’s input data and relaying output commands to the conveyor and linear actuators. Features: 120 V Power distribution 12 V Power Supply 5 V Power Supply RS232 8 point Analog Input Expansion 20 Discrete Inputs 12 Relay Outputs

Programmable Logic Controller The PLC used was a Allen Bradley Micrologix 1400 It then used Allen Bradley RSLOGIX 500 Software

I/O Points Discrete Input: Discrete Output: Analog Input: Power Switch Linear Actuator Vibratory Feeder Conveyor Belt Analog Input: Line Breakout Sensor

Program

Sensor Scaling The sensor reads from 0-5V with white being lower voltage We used PID (proportional-integral-derivative) scaling -10V to 10V is has input minimum to input maximum at 0 to 16,383 Since we were just wanting 0 to 5V, we had to adjust the input min and max - making 0V 8,192 and 5V 12,287 The scaled Minimum to Maximum is the percentage of 0V to 5V with 0 being 0V and 100 being 5V The efficiency goes up by 20% for every volt

Next Program Step Once the switch is turned on, the conveyor will start automatically After the switch has been turned on, the feeder will have a delay time of 5 seconds before starting

Last Program Step Once the feeder and conveyor have started, the sensors output will be read If the efficiency is below 50% (under 2.5V) the actuator will then extend for 10 seconds If the efficiency is above 50% (over 2.5V) the block will continue down the conveyor

Maintenance Issues Downloading updated firmware to the PLC. Replacing fuses and relays in the PLC The conveyor belt will need preventive maintenance work, such as: lubricating bearings and monitoring belt tension.

Stretch Goals and Possible Upgrades Wire to Unitronics PLC To program the DeltaV system and be able to test the switch from PLC to DeltaV To use our HMI on the PLC to also show the visuals of the conveyor and block color Possible upgrades: Larger conveyor which could allow a wider range of block colors. More linear actuators allowing more assortment.

We would like to thank emerson process management for giving us this opportunity!!!