Automatic Counting & Packing of incense sticks using PLC

Posted by : Ganges (Admin)

At present we have many machines on making incense sticks. Machines are even faster in making the sticks, but the count & packing is done manually, which may have certain effects on the industry. So to overcome the effects the system should be automated. As Incense sticks are counted manually, the sticks may get damage in some cases. The automation process is required here so that the process is maintained in a proper order.

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As sticks are made faster the packing must be done in the same speed, else the storage problems arise in the industry. And also the fuel management becomes some what difficult. Depending on the demand of the product we have to choose the procedure to obtain required output. It can be done by increasing labor, but training makes a problem again to the new comers. So making the process automated all the difficulties may be overcome. So, we go for process automation for the counting & packing.

PROBLEMS IN EXISTING SYSTEM

Incense stick making machines are lot available in the areas now. These are once even made by hands but the present technology had made it to be faster using machines. We have some machines that make the incense sticks about 350 per min. So manual packing may lead to decrease in system production, leading to decrease in productivity and even may increase the storage cost.

The Present system of Counting & Packing of incense sticks has following disadvantages:

· Low production
· Storage problems
· Cost of product may increase
· Improper packing
· Wastage of product material
· Operating cost increases
· Product may damage
· Efficiency is not good

So, to overcome the problems in the present system of counting & packing, the process is automated using pneumatic systems with certain arrangement.

OPERATION

Automatic counting & Packing of incense sticks uses a simple arrangement as shown in fig. circuit diagram. Initially the process of operation is to be examined such that it suits for automation process. The required components are to be selected for the operation. The necessary arrangement is made based on the process sequence. Each element is placed at the location needed for the process and the circuit connections are made as in the circuit drawn for the process.

The power supply and the input connections from the sensors is connected to the PLC module and the corresponding output signals are given to the solenoid valves of each actuator. The program thus written in the computer is transferred to the PLC module using a data cable and is installed in to it. The program can be tested and viewed through the software to check the progress.

The PLC is now ready for the process execution with all the components connected. The PLC is kept in run position and the process is started by pressing the ON switch. This makes the circuit energize and process starts from counting.

When the switch is pressed in to ON position the motor with rotary drum, which drops the sticks while rotating. The sticks are arranged in a container at the top of the rotary drum such that only one stick will get in to the drum slot. The drum is slotted such that only at a moment one stick will enter and fall after 90 deg rotation. The speed of the motor is maintained at a rate of 10 to 15 rpm depending up on the count of the sticks. So as supply starts flowing motor rotates and the drum starts dropping the sticks down to the polythene sheet placed below it.

An optical sensor is placed between the drum and the cover sheet so that to count the no. of sticks falling in to the cover. The sensor signal is given to the counter in the PLC such that when the sensor light is broken then it will send an output signal as count to the counter. This makes the program to count the sticks that fell in to the cover using this sensor.

The counter used in the program is a down counter which will count from 10 to 0, when the count reaches 0 the signal is generated at the output which will make the further operation. Once the count is done the motor stops rotating as the supply is cut-off by the signal of ‘B’ cylinder when it reaches the position ‘B2’. The B- cylinder refers to the action of gripping & heating of the cover filled with the sticks at the side-1 part of the cover as shown in fig.

Then after this signal is given to the A-cylinder which will heat the cover at the top side (side-2 of the cover). It’ll heat and come back to its initial state and after this the D-cylinder will drag the cover gripped with the B-cylinder and make the other empty sheet of cover to be in the position of next one. The B-cylinder will de-grip the cover from position B2 to B1 and the D-cylinder will move back from position D2 to D1.

After this operation the signal is sent back to motor to turn ON and again the sticks starts falling from the drum and so the process continues to be done in the same way. The incense sticks are thus counted and packed with a PLC program of 8 steps and provides a good design of the product.

MERITS

The Automatic counting & packing of incense sticks has the following merits: