Overall Research Report

AUTOMATED TYRE SORTING SYSTEM USING
MITSUBISHI FX3U PLC CONTROLLER
ARNON LERDWONGPAISAN
FACULTY OF ENGINEERING
UNIVERSITY OF MALAYA
KUALA LUMPUR
2013
i
AUTOMATED TIRE SORTING SYSTEM USING MITSUBISHI
FX3U PLC CONTROLLER
ARNON LERDWONGPAISAN
RESEARCH REPORT SUBMITTED IN PARTIAL
FULFILLMENT OF THE REQUIREMENT FOR THE
DEGREE OF MASTER OF ENGINEERING
FACULTY OF ENGINEERING
UNIVERSITY OF MALAYA
KUALA LUMPUR
2013
ii
ORIGINALITY LITERARY WORK DECLARATION
Name of Candidate : Arnon Lerdwongpaisan
Registration/Matric. No : KGC 110001
Name of Degree : M.Eng.
Title of Project Paper/Research Report/Dissertation/Thesis (“this work”):
AUTOMATED TYRE SORTING SYSTEM USING MITSUBISHI FX3U PLC

CONTROLLER
Field of Study : Industrial Apply
I do solemnly and sincerely declare that:
1. I am the sole author/writer of this Work;

2. This work is original;
3. Any use any work in which copy right exist was done by way of fair dealing and for
permitted purpose and any except or extract form, or reference to or reproduction of
any copyright work has been disclosed expressly and sufficiently and the title of work
and its authorship have been acknowledge in this Work;
4. I do not have any actual knowledge nor do I ought reasonably to know that the making
of this work constitutes an infringement of any copyright work;
5. I hereby assign all and every right in the copyright to this work to the University of
Malaya (“UM”), who henceforth shall be owner of the copyright in this Work and that
any reproduction or use in any form or by any means whatsoever is prohibited without
the written consent of UM having been first had and obtained.
6. I am fully aware that if the course of making this Work I have infringed any copyright
whether intentionally or otherwise, I may be subject to legal action or any other action
as may be determined by UM.
Candidate’s Signature Date:
Subscribed and solemnly declare before,
Witness’s signature Date:
Name:
Designation:
iii
ABSTRACT
This research presents a case study of development of automated tyre sortation system by
using integration of Programmable Logic Controller with barcode system. The objective of
this research is to identify the possible improvements for tyre sortation system, increase
flexibility of tyre sortation system by changing from manual to fully-automated, reduce
hiring cost and the number of workers and reduce tasks of workers. Tyre sortation process
is performed manually which is not flexible and can cause the mistake of sortation.
Therefore, the manual sorting operation should be eliminated and the automated system
should be developed or designed. Mitsubishi FX3U was chosen to integrate with barcode
system and ladder diagram was designed to control the sorting operation. Laboratory test
was performed to test the operation of program. The test shows that the program can work
successfully. If this project is applied in the real process, it can increase flexibility, reduce
task and number of operator and can save hiring cost of around 71,280 USD / year.
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ABSTRAK
Kajian kes ini membentangkan pembangunan sistem penyusunan tayar automatik dengan
menggunakan integrasi logik boleh aturcara dan sistem kawalan kod bar. Objektif kajian ini
adalah untuk mengenal pasti penambahbaikan yang boleh dilakukan untuk sistem
penyusunan tayar, meningkatkan fleksibiliti tayar sistem penyusunan dengan menukar dari
manual ke separa automatik atau automatik sepenuhnya, mengurangkan pengambilan kos
dan bilangan pekerja, dan mengurangkan tugas-tugas pekerja. Proses penyusunan tayar
yang dilakukan secara manual adalah tidak fleksibel dan boleh menyebabkan kesilapan
penyusunan. Oleh yang demikian, operasi susunan manual hendaklah dihapuskan dan
sistem automatik perlu dibangunkan atau direka sebagai penggantian. Mitsubishi FX3U
telah dipilih untuk mengintegrasikan dengan sistem kawalan kod bar dan gambarajah
tangga direka untuk mengawal operasi susunan. Ujian makmal telah dijalankan untuk
menguji pengoperasian program ini. Dapatan menunjukkan bahawa program ini boleh
bekerja dengan jayanya. Jika projek ini digunakan dalam proses yang sebenar, ia boleh
meningkatkan fleksibiliti, mengurangkan tugas dan bilangan pengendali, dan boleh
menjimatkan kos menyewa sebanyak 71.280 USD / tahun.
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ACKNOWLEDGEMENT
Firstly, I would like to convey my highest gratitude towards my project supervisor Dr.
Mahidzal Bin Dahari for his advice and support, and direction throughout this dissertation.
He has provided useful insights and comments during the research work. I would also like
to thank all the Faculty of Engineering lecturers for their help and guidance during my
academic program at University of Malaya. Unforgettably, I would like to thank you for
AUN SEED-Net JICA who provide scholarship and give me a chance to continue Master
degree.
Secondary, I would like to thank Mr. Vichit Lertwongpaisarn, Mr. Vanichaya, and staffs in
Thai Bridgestone Co., Ltd. in providing information and guidance for completing my
research. Additionally, I do not forget my assistant in laboratory who supported in
completing this research study and my family that they give me will power to struggle any
obstacles for my research.
Finally, I have no words that are adequate to express my heartfelt thankfulness for all you
have done for me. I love and respect you all.
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TABLE OF CONTENT
ABSTRACT ii
ABSTRAK iii
ACKNOWLEDGEMENT iv
TABLE OF CONTENT v
LIST OF FIGURES vii
LIST OF TABLES xi
CHAPTER1: INTRODUCTION 1
1.1 Introduction 1
1.2 Problem statement 4
1.3 Objective 4
1.4 Scope of study 4
1.5 Expected result 5
1.6 Research plan 5
CHAPTER2: LITERRATURE REVIEW 7
2.1 History of company 7
2.2 Automation system 8
2.3 Programmable Logic Controllers 11
2.4 Mitsubishi PLC 16
2.5 Hardware 17
2.6 Barcode system 22
2.7 The historical research of automation field and automation sorting system 26
2.8 Conclusion 32
CHAPTER3: METHODOLOGY 33
3.1 Introduction 33
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3.2 Current operation of tyre sortation process 33
3.3 Research procedure methodology 35
3.4 Detail of research procedure methodology 37
3.5 Concept of design process improvement 38
3.6 Integration of barcode reader with FX3U Mitsubishi PLC 43
3.7 Program design concept 48
CHAPTER4: RESULT AND DISCUSSION 50
4.1 Actuator system design 50
4.2 Program design 51
4.3 Laboratory test 67
4.4 Cost reduction prediction 72
4.5 Summary 72
CHAPTER5: CONCLUSION AND SUGGESTION 73
5.1 Conclusion 73
5.2 Suggestion 74
REFFERENCES 75
APPENDIX 77
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LIST OF FIGURES
Figure1.1 Current process of tyre sortation system 3
Figure2.1 Positional sketch 8
Figure2.2 Components of control part 10
Figure2.3 Opened control system 10
Figure2.4 Closed loop or feedback control system 11
Figure2.5 Basic components of PLCs 14
Figure2.6 Ladder logic diagram for the push-button switch 16
Figure2.7 Inductive proximity sensor 17
Figure2.8 Capacitive proximity sensor 18
Figure2.9 Through-beam sensor 19
Figure2.10 Retro-reflective Sensor 19
Figure2.11 Diffuse sensor 19
Figure2.12 Hydraulic cylinders 20
Figure2.13 Major and Minor area 21
Figure2.14 2D barcode 24
Figure2.15 3D barcode 24
Figure2.16 Barcode system 26
Figure3.1 Tyre's sizes 34
Figure3.2 Tag code of tyre 35
Figure3.3 Research study flowchart 36
Figure3.4 Sequence of operation 41
Figure3.5 New design concept 42
Figure3.6 Barcode reader HT700RB series 43
Figure3.7 PLC Mitsubishi FX3U 43
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Figure3.8 RS-232 wire port connector 44
Figure3.9 Barcode tag 45
Figure3.10 iVu Barcode Reader (BCR) 46
Figure4.1 Actuator system 50
Figure4.2 Double acting cylinder 51
Figure4.3 START section 56
Figure4.4 READ BARCODE section 57
Figure4.5 RS2 instruction 57
Figure4.6 COMPARE section for tyre number1 (13 inches) 58
Figure4.7 OPERATE and OUTPUT section for tyre number1 (13 inches) 60
Figure4.8 Ladder diagram 61
Figure4.9 Aid of sketch of equipment connection 67
Figure4.10 Real equipment connection 67
Figure4.11 Hardware lamp connection 68
Figure4.12 Switch set 68
Figure4.13 Connection of PLC 69
FigureA1. Solenoid valve 78
FigureA2. Working position of control valve 78
FigureA3. Port of control valve 79
FigureA4. Example of valve's name 80
FigureA5. Table of software 82
FigureA6. Create new project 82
FigureA7. Select type of PLC 83
FigureA8. Select sub-type of PLC and click ok to create new project 83
FigureA9. Table for new project 84
FigureA10. Project menu function 84
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FigureA11. Edit menu function 85
FigureA12. Find/Replace menu function 85
FigureA13. Convert menu function 86
FigureA14.View menu function 86
FigureA15. Online menu function 87
FigureA16. Tool menu function 87
FigureA17. Window menu function 88
FigureA18. Help menu function 88
FigureA19. Connection amount load, load inverse and out 89
FigureA20. Example of "AND" function 89
FigureA21. Example of "OR" function 90
FigureA22. Example of Load Pulse function 90
FigureA23. Example of Load Trailing Pulse function 91
FigureA24. Example of SET and RESET function 91
FigureA25. Example of TIMER function 92
FigureA26. Example of counter function 92
FigureA27. Example of INC and DEC function 93
FigureA28. Example of MOV function 93
FigureA29. Characteristic of compare function 94
FigureA30. Example of compare function 94
FigureA31. Characteristic of ADD, SUB, MUL, and DIV function 95
FigureA32. Example of ADD, SUB, MUL, and DIV function 96
FigureA33. ASCII data of barcode tag for tyre size 13 inches 96
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FigureA39. 32 bits data of barcode tag for tyre size 13 inches 99
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LIST OF TABLES
Table1.1 Research plan 6
Table2.1 Comparison between conventional relay system and PLCs 12
Table3.1 Detail of research procedure methodology 37
Table3.2 Function of equipment 39
Table3.3 Specification of barcode tag number 44
Table3.4 iVu specification 47
Table4.1 Set/Reset function 52
TableA1. ASCII code table 77
TableA2. Code definition 79
TableA3. Manual actuator 80
TableA4. Mechanical actuator 81
TableA5. Electromagnetic actuator 81
TableA6. Combine actuator 81
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CHAPTER 1
INTRODUCTION
1.1 INTRODUCTION
During the last decades, the capability of technological for performing in sorting or grading
was increased continuously. Nowadays, many devices for inspection are used for specimen
machining or object characterization over an extended scale range. These devices are
provided with servo-controlled positioning and required level of resolution. The processes
of operation system are complex structures with numerous steps may be transferred several
times from an instrument to another one(Jacquot, 2011).
Machine visions are an efficient method for noncontact sensing of many physical
quantities. The principle application of vision is to automate inspection processes. They can
be used for stacked bar codes and also included other type identification processes. For
example, machine vision system can be used to inspect for sorting a limited variety of
products moving on a conveyor belt, this process is not required any identification codes on
product because it detects on the geometric of products. Industries usually use machine
vision installations to perform a variety of automated inspection tasks which are either on-
line in-process or on-line post-process. Normally, vision system is applied for mass
production. Typical of tasks can be done such as dimensional measurement, verification of
the presence of components and detection of surface flaws and defects and so on(X. Cheng,
2003).
1
This research project focused on a case study from one company which produces tyres in
Thailand. This feasibility study has been focusing on tyres sortation system because the
process is performed manually by workers. The problem is that sortation line is not flexible.
Possible automation system and design software or simulations were suggested to improve
the performance. Therefore, semi-automated or fully-automated should be applied. Figure
1.1 shows the current process of tyre sortation system which is performed manually, each
station has one worker to press the button of actuator to hit tyres when they are sorted.
Worker will see the number of barcode that indicates the size of tyres.
2
Tires from curing process
Figure 1.1 Current process of tyre sortation system
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1.2 PROBLEM STATEMENT
This research project focuses on the sortation system of the company that sorts the different
size of internal diameter of tyres which are classified into 13 inches to 18 inches. Sortation
process of the company will only sort internal diameter but external diameter and thickness
of tyre will be a duty of supplier or distribution substitute. The study investigated low
flexibility of the process and found the difficulty for the workers to observe the barcode of
each size of tyres, this may cause the mistake of sortation process. Therefore, the
implementations of automation to eliminate manual operation should be performed. In
addition, after automation is applied, the number of workers can be reduced or terminated.
1.3 OBJECTIVE
• To identify the possible improvements for tyre sortation system.
• To develop tyre size sensors for sortation of the various sizes of tyre.
• To increase the flexibility of tyres sortation system by changing from manual to
semi-automated or fully-automated.
• To reduce hiring cost and the number of workers.
• To reduce tasks of workers by changing sortation process to automated system,
workers can be used for the other job.
1.4 SCOPE OF STUDY
The scope of this study is to investigate the adequate and possible automation system to
replace the manual operation of tyre sortation system. The software program of PLCs
integrated with barcode system will be designed. Actual test might be performed in the real
4
process, otherwise, the laboratory test or simulation will be done instead. The real
application in industry depends on consideration of the company.
1.5 EXPECTED RESULT
An expected goal of this research is to design an automated tyres sortation system. This
system may be applied in the real process in industry to achieve high accuracy,
repeatability, flexibility, increase the productivity and reduce time and hiring cost.
Anyway, if it does not apply in the real process, laboratory test and simulation method will
be done.
1.6 RESEARCH PLAN
1.6.1 Study on tyre sortation process.
1.6.2 Perform data collection.
1.6.3 Define the problem.
1.6.4 Create the way to solve the problem.
1.6.5 Design the software program to operate the system.
1.6.6 Test the program.
1.6.7 Measure the result of improvement.
1.6.8 Assess and conclude the operation result.
5
Table 1.1 Research plan
2012-2013
No Research plan Nov Dec Jan Feb Mar Apr May June
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
Study on tyre sortation

1
process.
Perform data
2
collection.
3 Define the problem.
Investigate the way to

4
solve the problem.
Design the software
5 program to operate the
system.
Test the program and

6
simulation.
Measure the result of

7
improvement.
Assess and conclude

8
the operation result.
6
CHAPTER 2
LITERATURE REVIEW
This study is to develop program design and test the system of automated tyre sorting
system by using appropriate hardware and software Mitsubishi developer which has
involved theory and previous research. The detail of this chapter will cover history of
company, automation system, Programmable Logic Controller, Mitsubishi PLC, hardware,
barcode system and the historical research of automation field and automated sorting
system.
2.1 HISTORY OF COMPANY
Bridgestone is the leader of tyres manufacturer in the world, the original plant (company)
was established by Shojiro Ishibashi in Kurume, Japan in 1931 which was the first local
tyre supplier for the Japanese automotive industry. Name "Bridgestone" came from Shojiro
Ishibashi, his name means "stone bridge." Headquarters of Bridgestone were relocated to
Tokyo in 1937. In 1942, the name was changed to the Nippon Tyre Co., Ltd., but was
renamed Bridgestone Tyre Co., Ltd. in 1951. Bridgestone achieved a U.S. production on
purchasing of a plant in LaVergne, Tennessee, belonging to the Firestone Tyre & Rubber
Company in 1983 and became Bridgestone Corporation in 1984 and expand the market
segment of tyre business to worldwide. Mr. Noboyuki Takamura is the general manager of
Bridgestone plant in Thailand which is established in 1967 and started production on
January 22, 1969, head office is located in Rama IV road, Bangkok. Nowadays,
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Bridgestone has two plants in Thailand which are Rangsit plant (established in June, 1967)
and Nongkhae plant (established in October, 1993). Rangsit plant produces tyres for
automotive for commerce, large automotive tyres and aircraft tyres and Nongkhae plant in
Saraburi produced tyres for automotive cars and pick up cars.
2.2 AUTOMATION SYSTEM
Automation system is the system or mechanism that is controlled by program and capable
to work automatically. The design of automation system starts from the study of the
problem statement in the work station and tries to set the equipment and software program
to test or simulate the system before the actual implementation. The basic components of
automation system can be divided into input, process and output. The design can be
perform easily by positional sketch to show the position of equipment and to understand the
real work station. Figure 2.1 is the example of positional sketch.
Figure 2.1 Positional sketch
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The design of automation system for any workstations has following step.
1. Study on the original and real system to understand the characteristic and
statement of the process.
2. Design the movement of equipment and select the power equipment. Sketch the
equipment to show the function and position and step of working condition.
3. Analyze the control signal that needs knowledge on electrical and program.
4. Design pneumatic or hydraulic system (depend on the type of work). Select the
appropriate detector and control equipment to perform wiring diagram.
5. Install equipment and test.
The purpose of automation system in industry is not only to increase productivity and
reduce cost but also increase the production efficiency in the part of quality and flexibility
of production system. For example, automotive industry uses expert human to perform
assembly, error is about 1-1.5%, but when automation system is applied by using robot and
error detection, error is reduced to 0.00001%. Automation system is also appropriate for
danger workstation, refinery, chemical industries and so on. Automation system has
become the main thing for rapid production. The importance is to control the quality
requirement. Automation systems are widely used in many industries such as
Programmable Logic Controller (PLC) or Distributed Control System (DCS) and
Supervisory Control and Data Acquisition (SCADA). However, automation system in
industry needs to integrate with computer and technology to achieve high efficiency of the
process(GROOVER, 2008).
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The main components of automation control system can be divided into 2 parts are
1. Control part: the function of control part is to convert external signal that is sent
to the system or input to appreciate signal for driving output or actuator to control the
system. In general, control part composes of receiver, detector, amplifier and controller as
shown in figure 2.2.
Figure 2.2 Components of control part
2. Output: the part that receive the signal from control part to drive hardware such
as solenoid valve, motor, bulb and so on.
Automation control system can be divided into two types:
1. Opened loop control system: the system that transfers signal to controller only
one way and has no feedback from output, it is the easiest system.
Figure 2.3 Opened control system
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2. Closed loop or feedback control system: the system that transfers signal to
controller and read feedback from output to compare and control output to work in the
desired condition.
Figure 2.4 Closed loop or feedback control system
2.3 PROGRAMMABLE LOGIC CONTROLLERS (PLCs)
2.3.1 History of PLCs
Programmable Logic Controllers or PLCs were invented by GM (General Motors)
company of United State to replace the conventional electric circuit that was using in
company. PLCs were first produced to distribute in United State in 1969. PLCs were
developed later in Japan after Omron Company succeeded in producing of Solid State
Relay in 1975. Five years later, PLC was widespread distribution in the market of industrial
organization.
2.3.2 What are PLCs?
PLCs are the Solid State equipment controlled by logic function. The operation of PLCs is
similar to the operation of computer. Basically, PLCs compose of equipment called Solid
State- Digital Logic Elements to make decision in logic system. PLCs are used to control
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the operation of machine in industries. Nowadays, many industries generally apply PLCs to
control the production system instead of the conventional relay circuit because of the PLC
is the microprocessor of electronic device and the programming is similar to general
program computer which differs from the wire installation of conventional relay systems.
Therefore, PLCs control systems can be easily changed the conditions of programs which
only modifies programs in memory unit but the conventional relay systems must be
reinstalled if we need to change the condition of systems. In addition, PLCs also have
higher efficiency in analyzing than the relay systems. They can control many types of work
and also can transfer the signals with other devices.
Table 2.1 Comparison between conventional relay system and PLCs
Conventional relay system PLCs
System Control Difficult Easy
Modification Difficult Easy
Connection with external Difficult because of much Easy because of lease wiring
equipment wiring
Lifetime Shorter because of higher Longer because of lower
movement part movement part
Speed Slow Fast
Installation Take long time Take short time
Working for complicated Difficult, must use many Easy
system relays
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2.3.3 Structure of PLCs
PLCs were designed for control work in industries that must be enduring with temperature,
humidity, dust, force, vibration and so on. PLCs compose of Control processing Unit
(CPU), memory, receiver unit, transfer unit and program device. Memory of PLCs
composes of Random Access Memory (RAM) and Read Only Memory (ROM), RAM's
function is to store the program and data of user, ROM's function is to store the program
for operation of PLCs which has small battery connected to maintain the data, RAM is
suitable to use for machine testing that needs to change or correct program frequently
because reading and writing program into RAM can be performed easily. CPU is the brain
of PLCs, inside CPU composes of many logic gates and Microprocessor-based that are
used to replace equipment such as relay, counter, and timer for user to build ladder logic.
CPU receives input data from sensing devices and store in memory, data will be transferred
to control devices. DC current source will produced low level voltage that is used by
processor and I/O modules.
Input and output unit (I/O Unit) will be connected with controller to receive signals and
transfer to CPU for processing and transfer to output unit. External input signal from
switches or detectors will be transformed to appropriate signal for transfer to CPU. Output
unit will receive signals from processing of CPU and use them to control hardware such as
motor, solenoid valve or bulb(Tancheewawong, 2012).
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Input Output M
device device
S
Processor Memory
Input Output
Power
unit unit
supply
Figure 2.5 Basic components of PLCs
2.3.4 PLC Operating
1. Receive input signals from input devices which can be pushbutton switches or sensors
for analog signal.
2. The signals from input devices will be adapted for understandable processor and it will
be stored in memory.
3. The processor will run the program step by step which starts from the first until the end
in memory. The condition of the program will be generated by using the statuses of input
devices.
4. Output unit transforms the output statuses to be the signals that can control and transfer
to output devices.
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5. Output devices which can be lamp, motor, control valve and so on will be controlled by
signals that are sent from output unit.
2.3.5 Programming the PLC
Programming is the process which the user enters the control instructions to the PLC
through the programming device. The instructions of PLC programming have three
languages such as
- Control System Flowchart or Function Block
- Ladder Diagram
- Statement List
Ladder diagram is the basic language which was used for small PLC to replace relay
devices, timer and counter in ON/OFF control. Function block and Statement list are high
language application that uses for complicated control or mathematical calculation. PLC
programming consist of steps which are
1) Specification is the detail of work that we need to control it.
2) Design can be shown by Function chart or Displacement Step Diagram and have
to show devices, installation, and circuit diagram.
3) Programming to control the work operation.
4) Commissioning used to test the working of program with the operation to detect
the error for correcting before it will be used.
In this section, we would like to show the basic programming of PLC by using Ladder
diagram in figure 2.
15
Figure2.6 Ladder logic diagram for the push-button switch
X1(normally open) and X2(normally close) are input contacts, and Y is a load in the
diagram which can be lamp, motor, solenoid valve and so on. Note Y also serves as an
input contact to provide the power connection. If we press switch X1, the signal will
transfer to a load Y (assume Y is a motor). Motor will run immediately and its contact also
holds the signal of system to allow motor run continuously. When we press switch X2, the
signal will be cut and motor will stop(Jack, 2005).
2.4 MITSUBISHI PLC
Mitsubishi is the one popular brand used in automation process in many factories. The
basics PLC of Mitsubishi are not different from the other brand. In addition, Mitsubishi
PLC can be applied broadly from simple to complicated process which depends on the type
of PLC. In general, the operation of processes in factories are mostly complicated, basic
PLC cannot be applied to run the processes. Therefore, data registers are required for these
processes, data register is the site to store the data or address when PLC is connected to the
other source of input such as barcode reader and camera. GX Developer is the software of
Mitsubishi PLC to design program, this software can be used to control every type of
Mitsubishi PLC for various types of process. The detail of using software is explained in
appendix.
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2.5 HARDWARE
2.5.1 Sensors
Sensors are used for a wide variety of the manufacturing process for collecting data in
feedback control. They are a transducer which is a device to convert a physical variable one
form to another one form. In this section, we will briefly discuss the types of sensors that
normally used in manufacturing application.
2.5.1.1 Inductive proximity sensor
Inductive proximity sensor can be used to detect metals by using inductive transformation.
The important components are Oscillator, Evaluator and Amplifier. At the tip of this sensor
has a high frequency of magnetic fields to detect nearby metal objects. If a metal object is
near the changing of magnetic field, current will flow in the object. This resulting current
flow will set up a new magnetic field to be the original magnetic field. The net effect is to
change the inductance of the coil in the inductive sensor by measuring the inductance of the
sensor can determine when a metal have been brought nearby.
Figure2.7 Inductive proximity sensor
17
2.5.1.2 Capacitive proximity sensor
Capacitive proximity sensor is similar to inductive proximity sensor but the operation is
different. Capacitive proximity sensor use Capacitance transformation due to the distance
and type of objects. It can detect both metals and non-metals which is specifically high
dielectric coefficients. The capacitance transformation of capacitive proximity sensor
occurs when objects are brought near the sensor. The proximity of any material near the
electrodes will increase the capacitance. This will vary the magnitude of the oscillating
signal and the detector will decide when this is great enough to determine proximity.
Figure2.8 Capacitive proximity sensor
2.5.1.3 Optical proximity sensor
Optical proximity sensor consists of two main components which are Receiver and Emitter.
Receiver normally uses Photo Diode and Photo Transistor and emitter normally uses LED
(Light Emitting Diode) to produce the light (red light or infrared). Optical proximity
sensor can be classified to be three types which are
1) Through-beam sensor. Receiver and Emitter are separated by using an object to
oppose the beam when it moves between receiver and emitter. This arrangement works
18
well with opaque and reflective objects with the emitter and detector separated by distances
of up to hundreds of feet.
Figure2.9 Through-beam sensor
2) Retro-reflective Sensor. Emitter and receiver are combined with polarizing
screens oriented at 90 deg. The light will be sent to reflector and reflected back directly to
receiver. If the light is obstructed by an object, the light does not pass through the screen in
front of the detector. So, that object can be detected.
Figure2.10 Retro-reflective Sensor
3) Diffuse sensor. This sensor is similar to Retro-reflective Sensor but the difference
is the light will be sent directly to an object and reflected back to receiver without reflector.
Figure2.11 Diffuse sensor
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2.5.2 Hydraulic cylinders
Hydraulic cylinders function by power transfer of liquid in linear direction. When power is
transferred into cylinder, cylinder will convert from hydraulic power to mechanical power
in the form of linear movement direction or rotary direction. Hydraulic cylinders can be
classified into 4 types:
1) Double Acting Single Rod Cylinder is two-way cylinder with one rod inside
cylinder.
2) Double Rod Cylinder is two-way cylinder with two rods connected with piston in
the middle.
3) Tandem Cylinder is two-way cylinder with two or more piston but only one rod.
This type can increase force of cylinder and it is normally used when pressure is limited
and area of piston cannot be changed to be bigger.
4) Duplex cylinder is two-way cylinder but rods are not connected together. It is
normally used when the position of piston is difficult to control(Pontri, 2009).
Figure2.12 Hydraulic cylinders
20
Double Acting Rod Cylinders are normally used in industries which converts from
hydraulic power (Gallon Per Minute: GPM and Pound Per Square Inch: PSI) to mechanical
power and can achieve the required speed. Speed and force of rod are defined by GPM and
PSI respectively. These two parameters affect to area of piston (Major area) and area of rod
(Minor area).
Figure2.13 Major and Minor area
Speed of rod for extending depends on flow rate of oil into cylinder which normally
measured in ft/min and can be calculated by:
Extending Rod speed, ft/min = (GPM x 19.25) / (area of piston (Major area), inch2)
Retraction Rod Speed:
Retraction Rod Speed, ft/min = (GPM x 19.25) / (area of rod (Minor area), inch2)
Flow rate of oil at rod end side (extending cylinder):
GPM = Rod speed, ft/min x (area of rod (Minor area), inch2) / 19.25
Flow rate of oil at piston side (retraction cylinder):
GPM = Rod speed, ft/min x (area of piston (Major area), inch2) / 19.25
21
Extending force:
F (pound) = Pressure (PSI) x (area of piston (Major area), inch2)
Retraction force:
F (pound) = Pressure (PSI) x (area of rod (Minor area), inch2)
2.6 BARCODE SYSTEM
Barcode was invented by Norman Joseph Woodland and Bernard Silver, student of Drexel
Institute of Technology in Philadelphia United State. The commencement of invention
started from Wallace Flint from Harvard School in 1932, he proposed product selection by
using bored card to divide categories of products but this idea was not developed until
Bernard Silver accidentally heard the manager of retail product company in Philadelphia
was consulting with the Faculty dean to supplement about data storage and clarification
experimental to afford convenience for retail business to manage stock. Bernard invited
Norman Joseph Woodland to join this challenge and in 1952, both of them invented
barcode after experimental for many years and they got patent on 7 October 1952. Barcode
was firstly produced in the form of circular shape similar to shooting butt. Nevertheless,
retail store in Kroger group in Cincinnati, Ohio state USA was the first company in the
world used this first form in 1967. Afterwards, barcode was developed and barcode
scanned was invented and firstly used in Marsh's supermarket on June 1974 and on 26 June
1974, Wrigley's Juicy Fruit gum was the first product to be scanned by barcode reader
because it was the first product of the first customer on that day.
Barcode is the sign used to replace and store any kinds of data by using binary codes. It can
be read by barcode reader (Optical machine-readable). Technology of barcode was used to
22
replace data entry by keyboard which has 0.01% error, but for barcode system, error is
reduced to 1/10,000,000. Data kept inside barcode mostly concern with the thing attached
by barcode, it is mostly used to clarify data of every product as we can see in the general
market. Barcode firstly used in the form of "Bar" or parallel lines with thickness and space
white and black colors, this is called 1D Barcode. Subsequently, barcode was developed to
have point, rectangular, hexagonal and other geometries form which are called "2D
barcode". Conventional barcode can be read by barcode reader. Currently, other equipment
and software ware developed to clarify barcode such as printing machine and smartphone.
Barcode is firstly used to control tram but it was not succeed for commercial business until
supermarket applied barcode to use for automated casher counter, this made barcode to be
widespread in the world. Barcode was widely used for other tasks that concerned with
automatic identification and data capture (AIDC). Modern barcode are made in the form of
Universal Product Code (UPC).
Nowadays, evolution of barcode system has undoubtedly developed both the form and
capability to store data. Barcode in this time has 1D, 2D, and 3D but the general barcode
used is 1D which is limited to store data. 2D barcode can store data more than the other
type and the shape is smaller. 2D barcode is used to store huge number of data included
Radio Frequency Identification (RFID) technology which used radio wave to inspect data
instead of laser. In addition, 2D barcode can be alteration in many applications, for
example, it can unbelievably store large file such as photos. 2D barcode that mostly used
has many types such as QR code, Data matrix, EZcode, Aztec Code and MS tag.
23
QR code Data matrix EZcode Aztec Code MS tag
Figure2.14 2D barcode
The purpose of 3D barcode is to eliminate the limit of barcode. The problem of barcode is
when barcodes are attached in atrocious environment such as very hot, very cold or dirty
from color or dust. 3D barcode is mostly used in heavy industrial such as machine and
automobile industrial. 3D barcode can be produced by using laser cut on metal or makes
the surface to be convex.
Figure2.15 3D barcode
Barcode is a good way to check selling products, selling point, price and inventory. We can
read barcode by using barcode reader which is faster than transfer data into computer or
eye vision. In general, we can see the uses of barcode in the grocery stores, book stores and
24
consumable stores. In Europe region, every truck run between French and Germany must
use barcode attached on the window to show identification card, permission document and
truck weight to the custom house to check easily and quickly, when the driver decreases the
speed of the truck, barcode reader will read and shown data on the computer
immediately(book, 2009).
Barcode system was seriously brought to use in Thailand by Thai Article Numbering
Council or TANC which is substitute organization under Thai Industrial Council. Barcode
system in Thailand uses 13 digits number which means thus
885: First 3 digits are Thailand's code.
XXXX: Next 4 digits are manufacturer's code or member's code.
XXXXX: Next 5 digits are product's code.
X: The last digit is used to ensure that the first 12 digits are correct. If the last digit
is wrong, that barcode cannot be read or interpreted data.
Barcode system will be integrated with PLC to classify sizes of tires and transfer signal to
PLC for this project. The main operations of barcode system are:
1. Light from barcode reader will be shined to barcode tag. Barcode reader consists
of light source, decoder, detector inside and cable to connect to the computer.
2. Receive the reflection and measure the number of light from barcode tag (black
bar will reflect light lower than the white space between them).
3. Barcode reader will convert the number of reflected light to electrical signal.
4. Electrical signal will be converted to usable data by decoder.
25
Figure2.16 Barcode system
2.7 THE HISTORICAL RESEARCH OF AUTOMATION FIELD AND
AUTOMATED SORTING SYSTEM.
A vision system was integrated to the manipulation system which consists of a conveyor
belt, objects moving on it, a robotic manipulator and a visual sensor above the conveyor for
applying on a real industrial manipulation. The applications for industrial are purposed to
utilize robotic manipulators. The combining vision and robotic applications have appeared
in many studies. There is a conveyor belt and a digital camera takes pictures of the object.
The system gets the captured image data and analyzes it and decides for next process which
depends on the result of the detection(Adıg¨uzel, 2007).
NBS Vision System was developed by Sensory Intelligence Group of Robotics System
which can be used in the Automated Manufacturing Research Facility (AMRF) to provide
information of the Real-time Control System and the Material Handling Workstation. A
vision system could be integrated with robotics for a robotic manipulation problem in
industrial settings. A problem could be formulated as combining the components which
consisted of a conveyor belt, objects moving on it, a robotic and a vision sensor above the
conveyor (Nashman & Chaconas, 1988).
26
The sorting system of grain color of rice seeds was studied to determine the parameters that
are influential with the effective of inspection for sorting. Background component were
installed to be opposite with inspector's lenses and two fluorescent lamps were located at
the top and bottom of sensor unit. The result shows that parameters affect to the best
performance of sorting. The controlled parameters are average grain velocity at 0.0817 m/s,
light intensity between 8,800-9,600 lux, the average background voltage 8.2 volt DC, focus
distance of sensing 123 millimeters, the average distance of background 54 millimeters,
voltage of feeder 80 volts, the average air pressure 2.5 bars, these parameters will result 74-
82% sorting efficiency (Rattanapussadeekul, 2006).
Automatic Rice Seeds Separator Machine was invented by using micro-controller to
control sorting system efficiently and can reduce wasteful rate of rice seeds more than
conventional machine, faster and more convenient. The process of rice seeds sortation has
many steps and need high volume number of workers. For conventional method, Rice seeds
will be fed and flowed into blank cavity. Wind is produced by manpower machine to blow
rice seeds and wind power is not stable, this is the cause that makes rice seeds become dirty
and waste. Automatic machine was developed to increase the efficiency of sorting process
and reduce the procedure of process by controlling speed of wind to be appropriate with
flow of rice seeds. The operations of automatic machine, rice seeds will be fed into blank
holder and choose the level of wind's speed which has high and low flow rate, wind's
speeds are controlled by motor's speed. The experimental was done to compare the
efficiency between conventional and automatic machine. The result shows 85.7%
efficiency for conventional machine and 92.5% efficiency for automatic machine (Anusorn
Srisawas, 2007).
27
Automatic Fish Measurement and Classification System using Video Image Analysis were
developed to achieve high efficiency in fish grading. Fish grading is now important process
for fishery industry, this process mostly uses human and it is not efficient enough.
Automatic Fish Measurement and Classification System will support fishery to get more
benefit, this system uses technology in image analysis from video camera by using digital
image processing. Fishes will flow on the conveyor belt and pass to processing system to
analyze the length of body and compare with database, the result will be the standard size
which is the beginning value of mechanic system to sort the size of fishes. Users can use
this program from user interface that is easily used without personal expertise to be usable
in the real fishery industry (Similan Arsaiphanish, 2007).
A Simple Material Selection Educational Training Kit Controlled by PLC was presented by
using the knowledge of conveyance system and automation operation applied to control the
operation of the system. The training kit has component both software program and
mechanic hardware of electro pneumatic and DC electric motor functions to control
conveyance system to the desired position. The experimental was done to determine
efficiency of training kit, error of selection test was a parameter, tested 30 times and 12
work pieces per one time to become 360 work pieces. The result shows that the training kit
was operated according to the control program and capable to sort different material work
pieces, the efficiency of material selection was 95% (Saithong Sriyotha, 2007).
Edward A Bruno presented a synthesis of available information on automated sorting of
plastics. The material includes technologies that are commercially available and those that
are still in the research phase of development. The information is broken into two
categories: macrosorting and microsorting. The macrosorting section deals with the sorting
28
of whole bottles or containers. The section covers the following technologies: infrared
spectroscopy, x-ray, laser-aided identification, and marker systems. The microsorting
section follows the sorting of plastic after it has been chopped into pieces. The section
covers the following areas: Sink float systems, froth-floatation, and selective dissolution.
As a final note, future areas of research are suggested(Bruno, 2005).
An automatic color sorting system was described for red oak edge-glued panel parts. The
color sorting system simultaneously examines both faces of a panel part and then
determines which face has the “best” color, and sorts the part into one of a number of color
classes at plant production speeds. Initial test results show that the system generated over
91 percent acceptable panels from automatically sorted red oak panel parts, which
exceeded target plant production goals. The color sorting system was developed in
cooperation with NOVA Technologies and is now commercially available under the name
of CESYS by Group Seven Systems(D. Earl Kline, 1997).
Baggage sorting is one of the major requirements for rapid processing in an airport. For
larger airport automated system is must to match with the dynamic world. But there are
many small to medium size airports handling between 1.5 and 6 million passengers a year,
still haven’t automated. For many of these airports, there are still big gains to be made – in
cost, time, efficiency and sorting quality – by introducing automated sorting system. The
problem for many of those airports is finding the right systems to do the job. Because in
many cases, solutions are designed primarily for the larger airports where much of the
automation market is to be found are not cost effective for lower volume environments, and
often those system cannot be accommodated within the space constraints of smaller
terminal buildings. In the present project, an automated baggage handling and sorting
29
system has been designed using microcontroller so that it could be cheaply implemented on
a small size terminal with a low cost. A small scale model of the project has also been
constructed. The sorting system is based on bar code reading and tracking of the baggage in
a terminal. The baggages are then diverted to their destined terminal using a gate control
system. The model can also be used in any packaging and distribution system(Aashique
Alam Rezwan, 2012).
Low cost parcel sorting system demonstrates the functional elements of an automated
sorting system by using a bar code reader (BCR).The adaptability of Bar Code Reader
(BCR) is destined for the recognition of the destination code through the bar code available
in the parcel and sorting them accordingly. A parcel usually comes with a consignment
number with a set of bar code representing them. The destination code must also be
included in the bar code set, so as to enable the recognition of the destination by the bar
code reader. The process of sorting can be continued by using a timed rolling system which
will be in the conveyer belt as a cross member which will drop down the parcel to the
destination box. There must be separate sorting system for incoming and outgoing parcels
to avoid complications(Ninja Agrawal1, 2013).
A.M Gaur, Rajesh Kumar, Amod Kumar and Dinesh Singh Rana described the automatic
control of disc type rheometer. This developed device will able to provide flexibility to
operator for testing of rubber. The operator has to just enter the duration of test and
parameters through man machine interface. All the operations will occur automatically
without any intervention in a prescribed sequence stored in programmable logic controller
(PLC). This developed apparatus is useful not only for testing purpose, but it can be used
for research for other types of materials also. With this state of art apparatus one can
30
control the quality of rubber for various applications such as tyre industry. Also this would
help to increase the production of rubber as automatic control comes which reduces the test
duration to few minutes only(A.M Gaur1*, 2010).
Nutdanai and Anake presents position and velocity control of a hydraulic cylinder in the
automated repeated opening and closing of doors and windows testing machine using fixed
displacement hydraulic pump coupled with servomotor in place of typical servo valve. The
opening and closing cycle of 10,000 to 100,000 must be achieved to represent realistic
working condition. The test machine consists of hydraulic power unit 4/3 directional
control valve and hydraulic cylinder attached to door swing arm linkage. Servomotor and
swing arm angular position was measured using optical encoder. The controller is PC
running LabVIEW Real-Time operating system using proportional torque control scheme.
Specimen was aluminum door frame set 73x193 cm in size. Results after 20,000 test show
that for generated polynomial trajectory tracking error was less than 3 degree and steady-
state error was less than 0.5 degree. Acceleration and deceleration time from 0 degree to 83
degree opening was 3 second and maximum pressure was 30 bars(Nutdanai Tanwirun,
2012).
A Programmable Logic Controller (PLC) is a specialized computer used for the control and
operation of manufacturing process and machinery. A junior/senior level PLC course in a
four-year electrical engineering technology institution mainly covers the following topics:
PLC hardware components, developing fundamental PLC wiring diagrams, basics of PLC
programming, timers, counters, program control instructions, data manipulation
instructions, math instructions, sequencer and shift register instructions, PLC installation,
editing and troubleshooting. After the lectures, students practice PLC programming using
31
RSLogix® from Rockwell Automation. Students are able to observe the operation of the
program and make necessary modifications as necessary. Towards the end of the semester,
students have learned the basic PLC programming instructions. It is a good time to enhance
their practical problem solving abilities by working on an extensive design project using
PLCs. This paper discusses three separate design projects aided with PLCs to solve
practical process and machinery problems in industrial environments(Guo, 2009).
The Top Cover Screw Floating Check at Final Inspection project is established to study and
check screws on the top cover of a hard drive. The purpose of this project is to reduce an
error of human’s eye. This image processing method is applied to this project to check and
compare the difference between original and test picture. The Top Cover Screw Floating
Check at Final Inspection project consists of 3 major parts: 1. Designing the Graphic User
Interface (GUI) process for a user. 2. Checking and showing a result of the level of top
cover screws. 3. Keeping the result in the database. From the experiments, the designed
program can successfully check and show the level of top cover screws. Finally, the
obtained result can be kept to the database as the objective of this project(KANITTA
HONGPAKMANOON, 2009).
2.8 CONCLUSION
Many research walk through the improve flexibility by using another tool on the
automation system, therefore make the feasibility to study the automation on many kind of
production process and manufacturing machine, one kind is hydraulic control system, also
widely used for improvement and install for increase performance to the system process,
due to this research considering to study the automation system in tyre production company
by applying PLC control for improvement on the tyre sortation system .
32
CHAPTER 3
METHODOLOGY
3.1 INTRODUCTION
In this study, tyre sortation process line of Thai Bridgestone needs to be improved.
Integration of Programmable Logic Controller (PLC) is chosen to solve the problem.
Therefore, software program design is applied to modify the sortation line from manual
operation to automated operation and laboratory test is performed to test the operation of
program. This chapter covers the topics include current operation of tyre sortation process,
research procedure methodology, detail of research procedure methodology, concept design
of process improvement, integration of barcode reader with FX3U Mitsubishi PLC and
program design concept.
3.2 CURRENT OPERATION OF TYRE SORTATION PROCESS
Tyre sortation process is performed to classify sizes of automobile tyres because tyres are
mixed after curing processes. Therefore, sortation process is required to sort different sizes
of tyres for distribution. Tyre's sizes of Thai Bridgestone Co., Ltd company can be
classified into mainly 6 sizes which is 13-18 inches measures from the internal diameter as
shown in figure 3.1, but the external diameter and thickness of tyres can be classified more
than 200 types, these sizes are produced to support various types of automobiles such as
sedan, pick up car, truck and so on.
33
Figure 3.1 Tyre's sizes
Tyre sortation process is performed manually which uses worker to operate. Sortation
process has 6 station divided for 6 sizes, workers stand at each station and tyres will be
moved on the conveyor belt, workers have to sort tyre's sizes by eyes to see tag code
attached on tyres and press the bottom to move cylinder forward to hit tyre for sortation.
This can be a cause of mistake in case of workers are unaware or forgetful and tyre's sizes
will be incorrectly sorted. In addition, overflow conveyor has been installed to prevent
when some of tyres are not sorted because of worker's mistake or process maintenance and
setup. This overall process is shown in figure 1.1.
Tag codes will be attached on tyres which is the sign for workers to classify sizes. Tag code
of Thai Bridgestone uses 9 digits shown in figure 3.2.
34
Figure 3.2 Tag code of tire
Tag code can be used to classify sizes and number of tyres. The first 2 digits classify sizes
which are 13-18 inches, the next 4 digits classify sequence number of tyres in one lot, and
the last 3 digits classify automobile types such as 100-155 are used for sedan. For example,
tyre 13 inches are produced 10,000 tyres in one lot and tag code 132345132 shows tyre size
13 inches, number 2,345 of 10,000 and used for sedan.
3.3 RESEARCH PROCEDURE METHODOLOGY
The methodology of this research project applies operation of programmable logic
controller (PLC) integrated with barcode reader to model automated tyre sortation system
and laboratory test is applied to simulate the overall system. These are performed to replace
real testing operation in industry. The research study flowchart is shown in figure 3.3.
35
START
Study on tyre sortation process
Perform data collection
Define the problem
Investigate the way to solve the problem
Design the software program to operate the system
Test the program and simulation

NO
Does the program work?
YES
Measure the result of improvement
Assess and conclude the operation result
END
Figure 3.3 Research study flowchart
36
3.4 DETAIL OF RESEARCH PROCEDURE METHODOLOGY
Detail of research procedure methodology in automated tyre sorting system using
Mitsubishi FX3U PLC controller composes of research procedure, operation objective,
method and tool as shown in table 3.1
Table3.1 Detail of research procedure methodology
Research procedure Operation objective Method and tool
1. Study on tyre sortation To know how is the current Observation on the
process. operation of process. operation.
2. Perform data collection. To know which parameter Check sheet and notebook
can be improved. writing.
3. Define the problem. To investigate and analyze Converse with operators.
the problem.
4. Investigate the way to To solve the problem. Study from manual PLC
solve the problem. book.
5. Design the software To run the system and Design program by using
program to operate the replace manual operation. software GX Developer
system.
37
Table3.1 Detail of research procedure methodology (continued)
Research procedure Operation objective Method and tool
6. Test the program and To test that does the Connect barcode reader and
simulation. program can work as desire? switches (replace sensors)
with PLC as input and
connect lamps (replace
solenoid valves) as output.
7. Measure the result of To study the result of Calculation
improvement. research project.
8. Assess and conclude the To monitor and predict for Compare the result before
operation result future improvement. and after improvement.
3.5 CONCEPT DESIGN OF PROCESS IMPROVEMENT
The manual operation of tyre sortation process should be eliminated. Integrated of
Programmable Logic Controller (PLC) with barcode system will be applied to automate the
system. Barcode reader is the input devices to receive barcode data number and transfer
data to PLC to operate process. Barcode readers will be installed for each sortation station
which 6 barcode readers will be used. Cylinders are the equipment used to sort for each
size and the movement of cylinder will be controlled by solenoid valve and hydraulic
system. Proximity sensors will be installed to check that tyre has reached to cylinder. The
functions of equipment are concluded in table 3.2.
38
Table3.2 Function of equipment
Equipment Function
Barcode reader Receive data input number of barcode tag.
Cylinder1 Sort tyre size 13 inches
Sensor X1 Check position of tyre size 13 inches
Solenoid valve Y000 Advance cylinder 1
Solenoid valve Y001 Return cylinder 1
39
Table3.2 Function of equipment (continued)
Equipment Function
The operation of each sortation station is separately controlled. This will result in
simplification the program and can also prevent bug of program, wrong sorting problem or
work in process in case of some tyre cannot be sorted because of defective program. The
operation of the system at each station is, when tyre moves pass barcode reader, barcode
reader will read barcode tag and transfer data to PLC to operate follow the designed
program, when proximity sensor is trigged because tyre move pass it, solenoid valve will
40
be commanded to control movement of cylinder to push tyre to the opposite path for
sorting, cylinders are driven by hydraulic system. The sequence of operation is shown in
figure 3.4 and aid of sketch of concept design is shown in figure 3.5.
Tyre feed
Barcode reader reads tag code
Classify size
PLC Sensor
Solenoid
valve
Cylinder
Figure 3.4 Sequence of operation
41
Figure3.5 New design concept
42
3.6 INTEGRATION OF BARCODE READER WITH FX3U MITSUBISHI PLC
Barcode is integrated with PLC as an input device to classify data of each size. The
important thing is how to manage data from barcode reader to easily connect with PLC?
Data from barcode must also be transformed to be usable for PLC. Barcode reader
HT700RB RS-232 series as shown in figure 3.6 and PLC Mitsubishi FX3U as shown in
figure 3.7 are used for experimental. Barcode reader and PLC are connected to transfer data
by RS-232 wire port connector as shown in figure3.8.
Figure3.6 Barcode reader HT700RB series
Figure3.7 PLC Mitsubishi FX3U
43
Figure3.8 RS-232 wire port connector
Each size of tyre is specified by tag number in barcode to classify size for PLC to operate.
Barcode tag number for each tyre's size is shown in table3.3 and figure3.9.
Table3.3 Specification of barcode tag number
Barcode tag number Specify
8851019010274 Tyre size 13 inches
44
Figure3.9 Barcode tag
Data from barcode are called ASCII characters which are the same number shown on
barcode tag. Data are continuously stored in Data register (D500), this is set by reading
command in ladder program of GX Developer software. ASCII data of each barcode tag for
each tyre's size are shown in appendix. However, ASCII data from barcode tag are not
usable with PLC. Therefore, data received from barcode must be transformed to be usable
for PLC. Data can be transformed by PLC and GX Developer software to become 16 bits
and 32 bits. In this case, 32 bits data are chosen to save the step of writing ladder diagram.
Transformation from ASCII to 32 bits data are decoding of PLC by using special function
inside microprocessor. Data are chosen and used to build ladder diagram. 32 bits data of
each barcode tag for each tyre's size are shown in appendix.
Barcode reader that should be applied for the real sortation process must be high
performance such as enable to read barcode tag in all direction, long distance scanning, and
45
fast reading because when tyres are put on the conveyor belt, it is very difficult to control
or set the direction of barcode tag to be readable for barcode reader.
Nowadays, performance of barcode reader has been developing to support wide variety of
industrial processes, iVu Barcode Reader (BCR) is a barcode reader used to read a variety
of barcodes and to optionally compare data to known values that can be used for this task
which is high-performance barcode reader of industry standard barcode. The sensor has an
integrated color touch screen display making installation, setup and configuration easy
without requiring a PC. It can read up to ten codes in any directions and a variety of
barcode types at one time, including: 2D barcode data matrix, 1D barcode (Code 128,
code39 and so on).
Figure3.10 iVu Barcode Reader (BCR)
The iVu BCR has an RS232 serial communications port that is used to output barcode data
to other applications. The user can enable or disable serial output. Table3.4 shows the
specification of iVu Barcode Reader (D, 2012).
46
Table3.4 iVu specification
Power Connection 12-pin Euro-style (M12) male connector
Accessory cord set required for operation;
QD cord sets are ordered separately.
Remote Display Connection 8-pin Euro-style (M12) female connector
(Remote Touch Screen Models Only) Accessory cord set required for remote
display; QD cord sets are ordered
separately.
Power Requirements Voltage: 10-30V dc
Current: 500 mA maximum (exclusive of
I/O load)
Output Configuration NPN or PNP determined by model
Sensor Lock Optional password protection
Output Rating 150 mA
Display Integrated Touch Screen models: 68.5 mm
(2.7") LCD Color Integrated Display 320 x
240 Transfer reflective
Remote Touch Screen models: See RD35
Remote Display specifications below.
Exposure Time (Decode) 0.1 milliseconds to 1.049 seconds
Weight Integrated Touch Screen models
approximately 0.295 kg
Remote Touch Screen models
approximately 0.204 kg
47
Table3.4 iVu specification (continued)
Operating Conditions Stable Ambient Temperature: 0° to + 50° C
Relative Humidity: 95%, max. relative, non-
condensing
Maximum operation distance 2m
Certifications
3.7 PROGRAM DESIGN CONCEPT
32 bits data of barcode are chosen to design ladder diagram. The concept of program design
is to read data from barcode tag and use them to classify tyre's sizes. After that, use
classified data to control operation of program and cylinders. The detail of concept of
ladder diagram can be briefly explained as follow:
1) Read barcode tag to receive 32 bits data to store in the first data register (let say
D500-D506) and move data to store in another data register (let say D200-D206). After
data are moved, the first data register must be reset or clear values to be able to receive new
data from the next coming tyre.
2) 32 bits data that are move to store in another data register (D200-D206) will be
compared by using compare function to classify which tyre's size has passed to the process,
in this step, data register (D200-D206) must also be reset or clear values to be able to
receive new data. Data of that size will be store in one more data register (let say D10).
Data comparison of each size will be the same.
48
3) After PLC has already known tyre's size, program must count the number of that
size and give signal to wait until sensor is trigged. D10 must be reset or clear values to be
able to receive new data.
4) After sensor is trigged, program will command solenoid valve to control cylinder
to push tyre to the sortation way. After one tyre is pushed, number of tyre inside program
must be decrease at once.
The program's operation of every tyre's sizes will be the same basic and ladder diagram will
be expressed and explained in chapter 4.
49
CHAPTER 4
RESULT AND DISCUSSION
This chapter presents the result of system development, including actuator system design,
ladder diagram design, and laboratory test to provide the possible automated tyre sorting
system. Overall detail will be explained and discussed on the result of development.
4.1 ACTUATOR SYSTEM DESIGN
Figure4.1 shows the actuator system which consist of six linear double acting cylinders (1,
2, 3, 4, 5 and 6) and six 5/2 way, double solenoid valves, detail and function of each
equipment were already shown in chapter3. The actuator system is driven by hydraulic
system and controlled by a typical PLC.
4 2
4 2 4 2 4 2 4 2 4 2
Y 000 Y 001
Y 002 Y 003 Y 004 Y 005 Y 006 Y 007 Y 010 Y 011 Y 012 Y 013
5 3
5 3 5 3 5 3 5 3 5 3
1
1 1 1 1 1
Figure4.1 Actuator system
In the real process, should have limit switch to check the position and control the
movement of cylinder. For example, if cylinder advances to the end position to push tyre to
50
the sortation way, cylinder will return immediately by function of limit switch which needs
to be designed in the actual implementation. In this program design, function of Timer is
used to replace limit switch by assume cylinder take 5 seconds to push tyre, this is for
convenience in laboratory test. The aid of sketch of double acting cylinder shown in figure
4.2
Figure4.2 Double acting cylinder
4.2 PROGRAM DESIGN
Program design of this study uses PLC controlled by ladder diagram and GX Developer
software of Mitsubishi is applied. Numbers are defined for each size to be easy for ladder
diagram design. Tyre size 13-18 inches are defined by numbers 1-6 respectively.
4.2.1 Set/Reset function
Set/Reset function is expressed to clarify ladder diagram how each variable is set and reset.
Set and Reset function are shown in table4.1
51
Table4.1 Set/Reset function
Section Variable Set function Reset function
Start X000 ALT M100 ALT M100
Read barcode D500-D510 RS2 ZRST
D200-D206 DMOVP T10
Compare size1 M20 D200.D202 D200 or D202
(13 inches) M21 M20.D204.D206 M20 or D204 or
D206
T10 M21 M21
D200-D206 DMOVP T11
D206
T11 M31 M31
D200-D206 DMOVP T12
D206
T12 M41 M41
52
Table4.1 Set/Reset function (continued)
D200-D206 DMOVP T13
D206
T13 M51 M51
D200-D206 DMOVP T14
D206
T14 M61 M61
D200-D206 DMOVP T15
D206
T15 M71 M71
D10 M21 T20
D1 D10 T1
Operate size1 T20 D10 D10
(13 inches) M10 D1.X001 T1
T1 M10 M10
M1 M10 T1
53
D10 M31 T21
D2 D10 T2
(14 inches) M11 D2.X002 T2
T2 M11 M11
M2 M11 T2
D10 M41 T22
D3 D10 T3
(15 inches) M12 D3.X003 T3
T3 M12 M12
M3 M12 T3
D10 M51 T23
D4 D10 T4
(16 inches) M13 D4.X007 T4
T4 M13 M13
M4 M13 T4
D10 M61 T24
D5 D10 T5
(17 inches) M14 D5.X005 T5
T5 M14 M14
M5 M14 T5
54
D10 M71 T25
D6 D10 T6
(18 inches) M15 D6.X006 T6
T6 M15 M15
M6 M15 T6
Y000 M100.M1 M1
Y001 M100 Y000
Y002 M100.M2 M2
Y003 M100 Y002
Y004 M100.M3 M3
Y005 M100 Y004

Output
Y006 M100.M4 M4
Y007 M100 Y006
Y010 M100.M5 M5
Y011 M100 Y010
Y012 M100.M6 M6
Y013 M100 Y012
4.2.2 Ladder diagram
Ladder diagram is programmed to run the process. In the design, ladder diagram is
separated to 5 sections are START, READ BARCODE, COMPARE, OPERATE and
OUTPUT, this is for easiness when we need to modify or correct program. Each section of
55
ladder diagram is explained for tyre size1 (13 inches) only because the other sizes are
performed the same configuration and overall ladder diagram will be shown later.
(1) START section
START section is used to turn on/off the process, it uses switch X000 to operate with ALT
function. When switch X000 is pressed first time, system will be turned on and when
switch X000 is pressed again, system will be turned off. Ladder diagram of START section
is shown in figure4.3
Figure4.3 START section
M100 is chosen to be holding relay, when M100 is turned on, output Y001, Y003,
Y005,Y007, Y011 and Y013 will be trigged (turned on) as will be expressed in output
section.
(2) READ BARCODE section
READ BARCODE section is used to receive data number of barcode tag. Ladder diagram
of this section is shown in figure4.4
56
Figure4.4 READ BARCODE section
The operation of this section can be explained:
(2.1) Contact M8002 (Initial pulse NO contact) is special relay which will turn on
one time when the system is turned on. In this case, if X000 is pressed, M8002 will turn on
one time to reset D500-D510 to prevent some remaining data disturbing the program,
function ZRST means zone reset.
(2.2) Function of receiving data from barcode reader is RS2 instruction which is the
function of FX3U type. The composition of RS2 instruction is shown in figure4.5
Figure4.5 RS2 instruction
57
Data will be store in D500 henceforward (D500-D506 for this case) and we use 32 bits data
(mentioned in chapter3) to classify tyre's size. Contact M8403 is called "Receive
Completion Flag" which normally used with RS2 instruction, when RS2 finishes receiving
data, it will turn on. In this case, when M8403 is on, it will:
- Cut signal to reset RS2 to be able to receive new data.
- Operate to move data from D500-D506 to store in D200-D206 for use them in
COMPARE section by DMOVP (Double bit move) function. D200-D206 will be reset in
COMPARE section.
- Reset D500-D510 to be able to receive new data by ZRST function.
- Reset M8403 itself to be able to work again.
(3) COMPARE section
The explanation of COMPARE section will be only explained for tyre number1 (13 inches)
because for the other sizes are also the same configuration. Ladder diagram of this section
is shown in figure4.6
Figure4.6 COMPARE section for tyre number1 (13 inches)
58
D200-D206 received data from READ BARCODE section. The operations of COMPARE
section are:
- If D200 is equal to 825571384 and D202 is equal to 809054512, M20 will be
turned on (M20 is used only to connect between D200 and D202 with D204 and D206).
- After M20 is turned on, if D204 is equal to 926036017 and D206 is equal to 3380,
M21 will be turned on.
- After M21 is turned on, it will move value 1 to store in D10, this is to know that
tyre size 13 inches (type1) has already passed to the process. D10 will be used in
OPERATE section.
- After M21 is turned on, T10 will count 0.3 second until complete and then reset
D200-D206 by ZRST function to be able to receive new data again.
(4) OPERATE and OUTPUT section
OPERATE and OUTPUT section should be explained together. Figure4.7 shows
OPERATE and OUTPUT section for tyre number1 (13 inches) and the operation can be
explained step by step.
59
Figure4.7 OPERATE and OUTPUT section for tyre number1 (13 inches)
- Contact M8000 (Run Monitor NO contact) is special auxiliary relay which is
turned on all the time.
- If D10 is equal to 1 (type1), D1 will be increased one (number of tyre come to the
process) by INCP (Increase pulse) function, T20 will count 0.3 second and then reset D10
to be able to receive new data by moving value 0 to D10.
- If D1 is more than 0 (have tyre come to the process) and sensor X001 is turned on
(tyre has already reached sensor), relay M10 is set.
- After M10 is set, M1 will be turned on, T1 will count 5 seconds (cylinder is
pushing tyre).
60
- After M1 is turned on, solenoid valve Y000 will be turned on (cylinder advances
to push tyre).
- Y000 is turning on, Y001 will be turned off.
- After T1 completed 5 seconds, M1 will be turned off, Y000 will be turned off,
Y001 will be turned on (cylinder returns), D1 will be decreased one (number of tyre
decreases after one tyre was pushed) by DECP (Decrease pulse) function, M10 will be reset
to be able to work again. All the operations are formed into a loop. The overall ladder
diagram is shown in figure4.8.
Figure4.8 Ladder diagram
61
Figure4.8 Ladder diagram (continued)
62
63
64
65
66
4.3 LABORATORY TEST
Laboratory test is done to test that the program can work successfully as desire. Program is
loaded to PLC and PLC is connected to model hardware. Aid of sketch of equipment
connection and real equipment connection are shown in figure4.9 and 4.10 respectively.
Figure4.9 Aid of sketch of equipment connection
Figure4.10 Real equipment connection
67
Hardware are modeled to replace real hardware of the process, this is because of limited
cost and cost reduction for testing. Lamps are used to replace solenoid valves (figure4.11),
switch set is used to replace START/STOP switch and sensors (figure4.12), PLC is
connected with barcode reader by RS-232 communication and connected to computer
laptop by PLC wire loader as shown in figure4.13.
Figure4.11 Hardware lamp connection
Figure4.12 Switch set
68
Figure4.13 Connection of PLC
Many test were performed to test the operation of the program, test method can be listed as
follow:
1) Press switch to start the system, all return lights (substitute of Y1, Y3, Y5, Y7,
Y11 and Y13) were turned on.
2) Scan barcode tag of tyre size 13 inches one time and press switch of sensor X1,
return light Y1 was turned off and advance light Y0 was turned on (cylinder1 is pushing
tyre). After 5 seconds, advance light Y0 was turned off and advance light Y1 was turned on
(cylinder1 returns).
3) Assumed that nine tyres size 13 inches come to the process by scanning barcode
tag nine times and then press switch of sensor X1 nine times, advance light Y0 could also
be turned on only nine times.
4) Assumed that ten tyres size 14 inches come to the process by scanning barcode
tag ten times. Tried to press switch of sensor X1 ten times, advance light Y0 did not turn on
69
just once (correct). Tried to press sensor X2 ten times, advance light Y2 could also be
turned on only ten times.
tag ten times. Tried to press switches of sensors X1 and X2 ten times per each, advance
lights Y0 and Y2 did not turn on just once (correct). Tried to press switch of sensor X3 ten
times, advance light Y4 could also be turned on only ten times.
tag ten times. Tried to press switches of sensors X1, X2 and X3 ten times per each, advance
lights Y0, Y2 and Y4 did not turn on just once (correct). Tried to press switch of sensor X4
ten times, advance light Y6 could also be turned on only ten times.
tag ten times. Tried to press switches of sensors X1, X2, X3 and X4 ten times per each,
advance lights Y0, Y2, Y4 and Y6 did not turned on just once (correct). Tried to press
switch of sensor X5 ten times, advance light Y10 could also be turned on only ten times.
tag ten times. Tried to press switches of sensors X1, X2, X3, X4 and X5 ten times per each,
advance lights Y0, Y2, Y4, Y6 and Y10 did not turn on just once (correct). Tried to press
switch of sensor X6 ten times, advance light Y12 could also be turned on only ten times.
9) Tried to scan barcode tag of tyre 13 inches one time and press switch of sensor
X1, Y0 could be turned on and Y1 could be turned off (cylinder1 was pushing), after 5
seconds Y0 was turned off and Y1 was turned on (cylinder1 returned). This was done with
five duplications.
70
five duplications.
five duplications.
five duplications.
seconds Y10 was turned off and Y11 was turned on (cylinder5 returned). This was done
with five duplications.
seconds Y12 was turned off and Y13 was turned on (cylinder6 returned). This was done
with five duplications.
71
4.4 COST REDUCTION PREDICTION
Hiring cost reduction can be predicted by eliminating sorting operators and try to calculate
as follow:
Number of operator = 6 operators
Wage = 450 baht/8 hr/shift or 15 USD (let say)
1 day = 3 shifts
Total hiring cost reduction = 6 x 15 x 3 = 270 USD/day
= 270 x 22 = 5,940 USD/month
= 270 x 22 x 12 = 71,280 USD/year
4.5 SUMMARY
This project may be applied in the real production process of the factory which depends on
consideration of the company. If this project is applied in the actual implementation, it will
increase accuracy of tyre sorting, repeatability, flexibility and productivity of sorted tyres.
Additionally, sorting time and hiring cost may reduce. However, time reduction need to be
measure by real application or 3D simulation software.
The success of this study is the development of program sequence control which can be a
prototype program for future improvement of model or actual implementation.
Additionally, this study lets researcher to learn more for usefulness of Programmable Logic
Controller which can be applied for future work as well.
72
CHAPTER 5
CONCLUSION AND SUGGESTION
5.1 CONCLUSION
This research project applies the integration of Mitsubishi FX3U PLC controller with
barcode system to model automated tyre sorting system. Researcher studied on the current
operation of tyre sortation system that sorts the different size of inside diameter of tyres
which are classified into 13 inches to 18 inches, the problem is the difficulty for the
workers to observe the barcode of each tyres and the operation are performed manually
which is not flexible and can cause the mistake of sortation process. Therefore, the manual
sorting operation should be eliminated and the automated system should be developed.
After the integration and connection between barcode reader and PLC was successful,
ladder diagram was designed to control the process based on data register from barcode
reader. After ladder diagram was accomplished, laboratory test was performed to model the
sortation process by connecting with the appropriate hardware. The test's result show that
the program ladder diagram could successfully operate in the correct condition. This
program can be a prototype program for future improvement of model or actual
implementation.
However, this research project also has obstacle (weakness point) which are automated tyre
sorting system needs data register from barcode reader, therefore, basic PLC is not
applicable and this makes the difficulty for integration and programming. Actual
73
implementation in the sortation process is quite difficult because of costing and need
agreement from the company and also takes long time to perform it. Some of theory of
PLC and barcode manual book is quite difficult to understand and need to take long time to
study. Programming and laboratory test need long time to perform for suitability and was
designed and corrected many time to be able to control the process. The application's cost
of this project cannot be calculated because it is not applied in the real sortation process.
5.2 SUGGESTION
Future improvement should be performed such as application in the real sortation process.
However, in the real application, program can be adjusted in the part of data register to be
suitable for higher performance barcode reader. If actual implementation cannot be
performed, laboratory test can be improved by integration of model conveyor system,
sensors and cylinders for more truthfulness. The integration of PLC and barcode reader can
be applied to sort for the other product that is applicable. Cost of the real application in the
future improvement should be considered and the real application may need many experts
in electrical and mechanical field.
74
REFERENCES
Adıg¨uzel, A. D. a. T. g. (2007). Vision Based Robotic Interception in Industrial

Manipulation Tasks. 7.
Anusorn Srisawas, P. T. (2007). Automatic Rice Seeds Separator Machine. 2.
book, O. U. m. (2009). Barcode configuration and commands manual (pp. 151).
D, R. (2012). iVu BCR Quick Start Guide (pp. 16).
GROOVER, M. P. (2008). Automation Production Systems, and Computer-Integrated

Manufacturing (third ed.). Pearson International Edition.
Hongsuwan, P. (2010). Learning PLC Mitsubishi (Second ed.): Satja Jarasrungraweeworn.
Jack, H. (2005). Automating Manufacturing Systems with PLCs.

Jacquot, P. S. a. M. (2011). Lensless vision system for in-plane positioning of a patterned
plate with subpixel resolution. 28, 2494-2500.
Nashman, M., & Chaconas, a. K. J. (1988). The NBS Vision System in the AMRF.
Research of the National Bureau of Standards, 93, 539-544.
Pontri, C. (2009). Industrial Automation. Burapha University.
Rattanapussadeekul, V. P. a. S. (2006). The Study of Grain Color sorting by Color Mark

Sensor. 1-9.
Saithong Sriyotha, B. U., Thotsapon Kengtone, Tawatchai Sawangnet, and Roengchai

Tummaman. (2007). A Simple Material Selection Educational Training Kit
Controlled by PLC. [October 17, 2007]. Department of Mechanical Engineering,
Faculty of Engineering, Rajamangkala University of Technology Isan, 7.
Similan Arsaiphanish, T. S. (2007). Automatic Fish Measurement and Classification

System using Video Image Analysis. 18.
Tancheewawong, N. (2012). Programmable Logic Controller. SST Thai-Japan

Technology.
A.M Gaur1*, R. K., Amod Kumar3 and Dinesh Singh Rana4. (2010). PLC Based
Automatic Control of Rheometer. 3(International Journal of Control and
Automation), 11-20.
Aashique Alam Rezwan, S. H., Pratyasha Prachurja and Minhajul Anwar. (2012). Design
and Construction of an Automated Baggage Sorting System. (2012 7th International
Conference on Electrical and Computer Engineering), 4.
75
Bruno, E. A. (2005). Automated Sorting of Plastics for Recycling. [Journal]. 13.
D. Earl Kline, R. W. C., Qiang Lu, Philip A. Araman. (1997). AUTOMATIC COLOR
SORTING OF HARDWOOD EDGE-GLUED PANEL PARTS. 6.
Guo, L. (2009). Design Projects in a Programmable Logic Controller (PLC) Course in

Electrical Engineering Technology. 10(the Technology Interface Journal), 1-10.
KANITTA HONGPAKMANOON, W. C., RATTIYAKORN THONGJUNJUA. (2009).
TOP COVER SCREW FLOATING CHECK AT FINAL INSPECTION. 1(Faculty
of Electrical Engineering), 1-72.
Ninja Agrawal1, S. S. (2013). LOW COST PARCEL SORTING SYSTEM WITH BCR:
AN AUTOMATED APPROACH. (International Association of Scientific
Innovation and Research (IASIR) (An Association Unifying the Sciences,
Engineering, and Applied Research)), 85-88.
Nutdanai Tanwirun, A. K. (2012). Servo Motor Based Hydraulic Control System for
Repeated Opening and Closing of Window and Door Testing Machine.
(Engineering Network of Thailand), 1-7.
76
APPENDIX
1. ASCII code
ASCII stand for American Standard Code for Information Interchange, it was developed by
ANSI (American National Standards Institute) which normally used for personal computer
(PC). ASCII uses 8 bits for one alphabet.
TableA1. ASCII code table
77
2. Solenoid Valve
Solenoid valve is used to control hydraulic system by using electric.
FigureA1. Solenoid valve
2.1 Valve symbols
The design of electro-hydraulic will only show the function of valves but the
internal structures will not be shown. Therefore, we need to know basic of valve symbols in
hydraulic system to be able to use them.
2.1.1 Position of control valve
1 1 Position valve
1 0 2 Positions valve
1 0 2 3 Positions valve
1 2 0 3 4 Positions valve
FigureA2. Working position of control valve
78
Position of control valve composes of normal position (0) and working position (1, 2, or 3).
2.1.2 Port of control valve
Port of valves in hydraulic system will be at normal position (0).
Valve 2 ways
Valve 3 ways
Valve 4 ways
Valve 5 ways
FigureA3. Port of control valve
TableA2. Code definition
Number Alphabet Meaning
1 P Fluid flow in
2, 4 A,B Fluid flow out for operation
3, 5 R, S To let fluid out
12, 14 Y, Z Port of control signal
79
2.2 Valve's name
Valve's name in hydraulic system can be called by port and position of valve.
Valve 2 ways and 2 positions
2/2 D.C. valve normally closed
FigureA4. Example of valve's name
2.3 Valve operation control
Valve operation control is done to change the position of valve defined by user.
TableA3. Manual actuator
Symbol Meaning
Use force to operate (normal symbol)
Hand press
Lever
Pedal
Pulling with locker
80
TableA4. Mechanical actuator
Symbol Meaning
Pressing
Spring return
Press rolling
Press rolling one way
TableA5. Electromagnetic actuator
Symbol Meaning
Solenoid operation and spring return
Solenoid operation and solenoid return
TableA6. Combine actuator
Symbol Meaning
Controlled by manual or electric

and returned by spring
Controlled by manual or electric to

open small valve and uses fluid of
small valve to control big valve,
returned by spring
81
3. Software GX developer
Figure A5. Table of software
Figure A6. Create new project
82
Figure A7. Select type of PLC
Figure A8. Select sub-type of PLC and click ok to create new project
83
Figure A9. Table for new project
Figure A10. Project menu function
84
Figure A11. Edit menu function
Figure A12. Find/Replace menu function
85
Figure A13. Convert menu function
Figure A14. View menu function
86
Figure A15. Online menu function
Figure A16. Tool menu function
87
Figure A17. Window menu function
Figure A18. Help menu function
88
3.1 Basic function
3.1.1 Load, Load inverse and Out function
Load and load inverse are the function to receive input from switch or sensor, contact of
load will be normally opened (NO) but contact of load inverse will be normally closed
(NC). Out is the end of function after load or load inverse receive input, out is normally
connected with output equipment such as motor, solenoid valve, coil, and bulb. The
example of connection amount load, load inverse and out is shown in figure A19.
Figure A19. Connection amount load, load inverse and out
3.1.2 "AND" function
"AND" function is the series connection of load function in figure A20.
Figure A20. Example of "AND" function
89
3.1.3 "OR" function
"OR" function is the parallel connection of load function in figure A21.
Figure A21. Example of "OR" function
3.1.4 Load Pulse function
Load pulse function will work only one time at uptime condition. For example in figure
A22, if we press switch X0 and remain its condition, output Y0 will be trigged at the first
time only one time.
Figure A22. Example of Load Pulse function
90
3.1.5 Load Trailing Pulse function
Load Trailing Pulse function will work only one time at downtime condition. For example
in figure A23, if we press switch X0, Y0 will not be trigged until switch X0 is released.
Figure A23. Example of Load Trailing Pulse function
3.1.6 SET and RESET function
SET function will be on output all the time until RESET function is trigged. For example in
figure A24, if X0 is pressed, Y0 will be on until X1 is pressed.
Figure A24. Example of SET and RESET function
91
3.1.7 TIMER function
TIMER function is used to prolong the time when the process is required. Example of
TIMER is shown in figure A25, when X0 is presses, after 1 second, Y0 will be on (T0 is
the sequence of TIMER and K10 = 1 second).
Figure A25. Example of TIMER function
3.1.8 Counter function
Counter function is used to count the work cycle of the program. Example of counter in
figure A26, X0 must be pressed 15 times to be on Y0 and press X1 1 time to reset counter.
Figure A26. Example of counter function
92
3.2 PLC Data Register
Data register (D) is the site to store data or address.
3.2.1 INC and DEC function
INC is the function to increase one value at a time and DEC is the function to decrease one
value at a time. Example in figure A27, press X0 to increase one value of D0 at a time and
press X1 to decrease one value of D0 at a time.
Figure A27. Example of INC and DEC function
3.2.2 MOV function (Data transfer instructions)
MOV is the function to transfer data. Example in figure A28, when X0 is pressed and then
value 1,000 will be move to store in D0.
Figure A28. Example of MOV function
93
3.2.3 Compare function (=,>, <, >=, >=)
Compare function is used to compare value of data to run program. The function can be
written as shown in figure A29.
Figure A29. Characteristic of compare function
Figure A29 can be read that "if D0 is equal to 2". Example of compare function is
explained in figure A30. Value of D0 is defined by X0. If D0 is less than 5, Y0 will be on.
If D0 is equal 5, Y1 will be on. If D0 is more than 5, Y2 will be on.
Figure A30. Example of compare function
94
3.2.4 ADD, SUB, MUL, and DIV function
ADD, SUB, MUL, and DIV are the function to calculate the value of data. ADD is plus,
SUB is minus, MUL is multiply and DIV is division. The function can be written as shown
in figure A31.
Figure A31. Characteristic of ADD, SUB, MUL, and DIV function
Figure A31 can be read that plus S0 by S1 and store in D. Example of ADD, SUB, MUL,
and DIV function is explained in figure A32. Value of D0 is defined by X0 and M8000 is
always on contact. The functions are Plus D0 by 5 and store in D1, minus D0 by 10 and
store in D2, multiply D0 by 2 and store in D3, divide D3 by D1 and store in
D4(Hongsuwan, 2010).
95
Figure A32. Example of ADD, SUB, MUL, and DIV function
4. ASCII Data
Figure A33. ASCII data of barcode tag for tyre size 13 inches
96
Figure A34 ASCII data of barcode tag for tyre size 14 inches
97
98
5. 32 bits data
Figure A39. 32 bits data of barcode tag for tyre size 13 inches
99
100
Figure A43 32 bits data of barcode tag for tyre size 17 inches
101
102

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AUTOMATED TYRE SORTING SYSTEM USING

MITSUBISHI FX3U PLC CONTROLLER

FX3U PLC CONTROLLER

RESEARCH REPORT SUBMITTED IN PARTIAL

FULFILLMENT OF THE REQUIREMENT FOR THE

DEGREE OF MASTER OF ENGINEERING

Name of Candidate : Arnon Lerdwongpaisan

Registration/Matric. No : KGC 110001

Name of Degree : M.Eng.

Title of Project Paper/Research Report/Dissertation/Thesis (“this work”):

AUTOMATED TYRE SORTING SYSTEM USING MITSUBISHI FX3U PLC

Field of Study : Industrial Apply

I do solemnly and sincerely declare that:

1. I am the sole author/writer of this Work;

Candidate’s Signature Date:

Subscribed and solemnly declare before,

Witness’s signature Date:

flexibility of tyre sortation system by changing from manual to fully-automated, reduce

manual ke separa automatik atau automatik sepenuhnya, mengurangkan pengambilan kos

meningkatkan fleksibiliti, mengurangkan tugas dan bilangan pengendali, dan boleh

menjimatkan kos menyewa sebanyak 71.280 USD / tahun.

research. Additionally, I do not forget my assistant in laboratory who supported in

obstacles for my research.

have done for me. I love and respect you all.

LIST OF FIGURES vii

1.2 Problem statement 4

1.4 Scope of study 4

1.5 Expected result 5

1.6 Research plan 5

CHAPTER2: LITERRATURE REVIEW 7

2.1 History of company 7

2.2 Automation system 8

2.3 Programmable Logic Controllers 11

2.4 Mitsubishi PLC 16

2.6 Barcode system 22

3.3 Research procedure methodology 35

3.4 Detail of research procedure methodology 37

3.5 Concept of design process improvement 38

3.6 Integration of barcode reader with FX3U Mitsubishi PLC 43

3.7 Program design concept 48

CHAPTER4: RESULT AND DISCUSSION 50

4.1 Actuator system design 50

4.2 Program design 51

4.3 Laboratory test 67

4.4 Cost reduction prediction 72

CHAPTER5: CONCLUSION AND SUGGESTION 73

Figure1.1 Current process of tyre sortation system 3

Figure2.1 Positional sketch 8

Figure2.2 Components of control part 10

Figure2.3 Opened control system 10

Figure2.4 Closed loop or feedback control system 11

Figure2.5 Basic components of PLCs 14

Figure2.6 Ladder logic diagram for the push-button switch 16

Figure2.7 Inductive proximity sensor 17

Figure2.8 Capacitive proximity sensor 18

Figure2.9 Through-beam sensor 19

Figure2.10 Retro-reflective Sensor 19

Figure2.11 Diffuse sensor 19

Figure2.12 Hydraulic cylinders 20