PLC Sorting Conveyor Trainer
(CT-032)

1.PLC module, 2.Manual control mode, 3.PLC control mode, 4.Alarm lamp, 5.Schematic Diagram with process sequence indicatio0n LEDs, 6.Hopper, 7.Arm, 8.Belt conveyor, 9.DC motor, 10.Pneumatic pistons, 11.Storage boxes, 12.Proximity sensors, 13.Suction Cup, 14.Photo electric beam sensors,15.Proximity sensors, 16.Storage drawer.

  • Working with PLC Programming languages Ladder Logic KOP/LAD, Function Block Diagram FUP/FBD, Structured Control Language SCL Corresponds to IEC 61131-3 ( KOP/LD, FUP/FBD, ST )
  • Conveyor belt (speed and directional control through its Geared DC Motor)
  • Counting, width measurement and material determination of pieces
  • Creating a program that will automatically sort parts according to their width and material type
  • Making controlled movements on single axis (forward, backward, position and speed control with the ability of slip and locking detection)
  • Dealing with related sensor and actuators
  • Fundamentals of pneumatic driven systems
  • Timing events
  • Industrial controllers
  • PLC Unit
    • SIMATIC S7-1200, CPU 1214C
    • Working memory: 75 kilobytes.
    • Processing times: 0.1 μs for bit operations, 12 μs for word operations, 18 μs for floating point arithmetic
    • Total remnant data memory (including timers, counters and flags): 2048 bytes
    • 1 x Ethernet/ProfiNet Interface
    • 14 x Digital inputs, 24 V DC
    • 2 x Analog inputs, 0…10 V
    • 2 x Potentiometers for controlling analog inputs
    • 10 x Digital outputs, 24 V DC
    • Hardware clock (real-time clock)
  • Encoder
    • Voltage: DC, 5-24 V
    • Output wave: double
    • Output Phase: 3
  • Dc Motor
    • Voltage: DC, 24 V
    • Power: 30 Watt
    • Gear ratio: 7.5
    • Speed: 3000 rpm
  • Piston cylinder
    • Double acting
    • Ø= 16 mm
    • Stroke: 100 mm
  • Semi-Rotary Drive
    • Double-acting
    • Rotation angle :0-180 deg
    • Operating pressure: 2-8 bar
  • Pneumatic Valve
    • Voltage: DC, 24 V
    • 5/2-way valve
  • Inductive Proximity Sensor
    • Wire type and power: 3-wire type 12-24VDC
    • Current consumption: Max. 10mA
    • Sensing distance: 8mm
    • Control output: PNP Normally Open
    • Response frequency: 350Hz
  • Capacitive Proximity Sensor
    • Wire type and power: 3-wire type 12-24VDC
    • Current consumption: Max. 15mA
    • Sensing distance: 8mm
    • Control output: PNP Normally Open
    • Response frequency: 50Hz
  • Photoelectric Beam Sensor
    • Supply Voltage: 6-36V DC
    • Sensing distance: 0-20 m
    • Wire Type: DC 3 Wire
  • PLC sorting conveyor trainer - (CT - 032)
  • Hard copy user manual
  • Laboratory PC

The DC transport station with products sorting conveyor is designed to demonstrate sorting methods of products by using PLC (programmable logic controller) which is used in real-life industrial plants or by using manual control mode. Besides using PLC system, the training unit can also be controlled manually through inserted pushbuttons on the training panel Within this training system, trainees will get exposed to sorting applications, PLC programming codes as well as PLC wiring diagrams. The training system comes with a pre-set programming code which can be altered by the user.

                                     
  • The trainer is divided into two control systems. The first one is controlling the system using programmable logic controller (PLC) while the second option is to control the system manually using push buttons on the panel for all of the actuators in the system.
  • The educational unit consists of a vertical panel that contains operation panel, PLC control panel, manual control panel and schematic diagram of the sorting system.
  • The horizontal part of the educational unit contains the process area which demonstrates a real-life sorting system.
  • The trainer is supplied with compressor to provide air for all of the pneumatic actuators.
  • The unit is supplied with service unit to adjust the supplied pressure before entering the trainer.
  • The trainer is supplied with metal and non-metal test parts made out of different widths to simulate products sorted by a PLC system.
  • The sorting system consists of hopper, proximity sensors, arm, rotary cylinder, suction cup, DC motor, belt conveyor, photo electric beam sensors, pistons and storages for the sorted and rejected parts.
  • The hopper where the test parts are fed to is supplied with a proximity sensor at its bottom to sense the existence of the parts within it.
  • The hopper is also supplied with a pneumatic piston to move the test parts depending on signals received from the proximity sensor.
  • The belt conveyor represents a real-life one used in industries. The conveyor speed could be adjusted easily using PLC or manually.
  • The arm moves by using a rotary cylinder attached to it. A pneumatic suction cup is attached to the arm in order to transport the parts from the hopper to the conveyor.
  • The conveyor is driven using DC motor which is supplied with encoder which aid sin sending feedback for the motor’s speed.
  • Two photo electric beam sensors are provided to determine the width of the parts giving signals to the PLC to perform the required sorting process. A proximity sensor is also provided to determine whether the part is metal or not.
  • Four pistons are used to push each sorted part to its convenient storage box.
  • Four storage boxes are used for the sorted test parts as well as a storage box for the rejected test parts.
  • The unit is supplied with a proximity sensor mounted at the end of the conveyor to count the number of the rejected test parts.
  • The sorting systems is provided with four counters to count the sorted test parts in the four storage boxes and one counter for the rejected material storage box.
  • The schematic diagram is supplied with LEDs for all the sensors and actuators included in the educational unit to indicate their status.
  • The unit is supplied with an alarm lamp as a safety measure to indicate whether the trainer is processing or not, aided with beeping facility to state any malfunctions in the system.
  • The trainer can be switched from PLC mode to manual mode easily from the operation panel.
  • The unit is supplied with emergency switch as well as trainer on/off switch.