University of Tennessee, Knoxville

TRACE: Tennessee Research and Creative

Exchange

Masters Theses Graduate School

8-2003

Sensor Based PLC Programming for a Discrete Event Control

System
Siva Kali Prasad Dasari
University of Tennessee - Knoxville

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Part of the Mechanical Engineering Commons

Recommended Citation
Dasari, Siva Kali Prasad, "Sensor Based PLC Programming for a Discrete Event Control System. " Master's
Thesis, University of Tennessee, 2003.
https://trace.tennessee.edu/utk_gradthes/1931

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To the Graduate Council:

I am submitting herewith a thesis written by Siva Kali Prasad Dasari entitled "Sensor Based PLC
Programming for a Discrete Event Control System." I have examined the final electronic copy of
this thesis for form and content and recommend that it be accepted in partial fulfillment of the
requirements for the degree of Master of Science, with a major in Mechanical Engineering.

William R. Hamel, Major Professor

We have read this thesis and recommend its acceptance:

Gary V. Smith, Arnold Lumsdaine

Accepted for the Council:

Carolyn R. Hodges

Vice Provost and Dean of the Graduate School

(Original signatures are on file with official student records.)

To the Graduate Council:

I am submitting herewith a thesis written by Siva Kali Prasad Dasari entitled

“Sensor Based PLC Programming for a Discrete Event Control System”. I have
examined the final electronic copy of this thesis for form and content and
recommend that it be accepted in partial fulfillment of the requirements for the
degree of Master of Science, with a major in Mechanical Engineering.

William R. Hamel
Major Professor

We have read this thesis and

recommend its acceptance:

Gary V. Smith

Arnold Lumsdaine

Acceptance for the Council:

Anne Mayhew
Vice Provost and
Dean of Graduate Studies

(Original signatures are on file with official student records)

 SENSOR BASED PLC

PROGRAMMING FOR A DISCRETE

EVENT CONTROL SYSTEM

A Thesis Presented for the

Master of Science

Degree

University of Tennessee, Knoxville

Siva Kali Prasad Dasari

August 2003
 ACKNOWLEDGMENTS

I wish to thank my wonderful parents Krishna and Banagaramma for their support

and guidance. I cannot, in anyway, repay my parents for their support and many

wonderful gifts.

I would like to thank my advisor Dr. William R. Hamel for his guidance and

patience during my master’s program. In addition, I appreciate all the students in the

Robotics and Electromechanical Systems Laboratory for their help during my entire

period as a master’s student. I am highly obliged to the committee members (Dr.

William Hamel, Dr. G. V. Smith, and Dr. A. Lumsdaine) for their support and

encouragement.

I am also thankful to The Providence Group, Applied Technology at Knoxville,

Tennessee, who supported this research and allowed me to complete my thesis. Last

but not the least I am deeply indebted to Mr. Ajit Deobhakta who introduced me to

various programmable logic controllers and tools that handle them.

ii
 ABSTRACT

In the manufacturing industry, automation in material handling has increased the

overall profitability of the product with an improvement in the quality and

productivity of the system. This is primarily due to two reasons. First, automation

reduces the total production cycle time, and second, it helps smooth flow of raw

materials and finished products to their desired location with little or no human

interference. But, such an implementation involves several problems. One

significant problem is the location of sensors that perceive the system environment.

A correct choice of sensors at precise locations enables the controller to collect the

required information and take a suitable decision that makes the system more robust.

Moreover, the sensor logic is vital to control the system.

This thesis addresses the sensor placement and control logic issues in an automated

material handling system that was developed by The Providence Group, Applied

Technology (TPGAT) at Knoxville, Tennessee. The proposed design prevents

deadlock and controller jamming. This is achieved by a suitable control on the

occurrence of events in the system. This solution also allows the controller to take

decisions for the smooth movement of material. In addition, recommendations for

an overall improvement in the structural aspects of the system are discussed.

However, additional sensors need to be installed to implement this design. Although

similar systems exist this thesis attempts a cost effective solution.

iii
 TABLE OF CONTENTS

CHAPTER ONE, INTRODUCTION..........................................................................1

1.1 Background..................................................................................................1

1.2 Problem statement and approach ...............................................................3

1.3 Discrete event system ..................................................................................4

1.4 Outline..........................................................................................................6

CHAPTER TWO, BASIC AUTOMATION DESIGN CONCEPT......................... 7

2.1 Overview ......................................................................................................7

2.2 Breakdown of the design into components .................................................9

2.2.1 Actuators and drive systems................................................................9

2.2.1.1 Pneumatic cylinders........................................................................9

2.2.1.2 Cylinder force requirements .........................................................11

2.2.2 Controller systems................................................................................11

2.2.2.1 Basic structure of programmable controller system....................11

2.2.2.2 Programming of PLC....................................................................13

2.2.3 Sensors...................................................................................................15

CHAPTER THREE, EXISTING DESIGN AND ANALYSIS ..............................19

3.1 Introduction ...............................................................................................19

3.2 Primary function of the system..................................................................20

3.3 Detailed system description ......................................................................22

iv
 3.3.1 Actuators ............................................................................................... 22

3.3.2 Sensors................................................................................................... 22

3.3.3 Tables .................................................................................................... 22

3.3.4 Control system....................................................................................... 22

3.3.5 Working principle.................................................................................. 24

CHAPTER FOUR, IMPROVED DESIGN AND ANALYSIS .............................. 28

4.1 Revised design ........................................................................................... 28

4.2 Structural ................................................................................................... 28

4.3 Programming............................................................................................. 29

4.4 Summary of logic complexity .................................................................... 32

CHAPTER FIVE, IMPROVED DESIGN AND PERFORMANCE .................... 33

5.1 Hardware setup ......................................................................................... 33

5.2 Software setup ........................................................................................... 33

5.3 Simulation.................................................................................................. 34

5.4 System states.............................................................................................. 36

CHAPTER SIX, CONCLUSION AND FUTURE WORK .................................... 43

6.1 Summary .................................................................................................... 43

6.2 Future trends ............................................................................................. 44

BIBILOGRAPHY........................................................................................................ 45

APPENDICES .............................................................................................................. 48

v
 Appendix A. Description of FBD programming .......................................................49

Appendix B. Description of Function Block CHDI...................................................82

VITA ..............................................................................................................................84

vi
 LIST OF TABLES

TABLE 1. TYPES OF MATERIAL HANDLING SYSTEMS ........................................................ 3

TABLE 2. TYPES OF ACTUATORS ..................................................................................... 10

TABLE 3. TYPES OF CONTROLLER SYSTEMS.................................................................... 12

TABLE 4. TYPES OF PROXIMITY SENSORS ...................................................................... 18

TABLE 5. CONTROL SYSTEM COMPLEXITY ..................................................................... 32

vii
 LIST OF FIGURES

FIGURE 1. CONJUNCTION OF DIFFERENT SYSTEMS............................................................2

FIGURE 2. AUTONOMOUS SYSTEM ....................................................................................4

FIGURE 3. BASIC FUNCTIONAL STRUCTURE OF PLC .......................................................13

FIGURE 4. COMPLETE MATERIAL HANDLING SYSTEM .....................................................19

FIGURE 5. PRESENT SYSTEM LAYOUT .............................................................................21

FIGURE 6. TABLE TC1 ....................................................................................................23

FIGURE 7. TABLES TC2, TC3, TC4 ................................................................................23

FIGURE 8. PROPOSED SYSTEM .........................................................................................30

FIGURE 9. INITIAL SETUP OF THE SIMULATION ................................................................34

FIGURE 10. THE STATE OF SYSTEM DURING MOTION OF PALLET FROM RLT TO TC1 ....38

FIGURE 11. DOWNWARD MOTION OF PALLET DURING RLT TO TC1 TABLE ..................38

FIGURE 12. MOTION OF PALLET FROM TC1 TO TC2 TABLE ...........................................39

FIGURE 13. MOTION PALLET FROM TC2 TO TC3 TABLE ................................................39

FIGURE 14. STATE OF SENSORS WHEN LOADED PALLET IS PRESENT ON TC3 TABLE ......40

FIGURE 15. MOTION OF PALLET FROM TC3 TO TC4 TABLE ...........................................40

FIGURE 16. MOTION OF PALLET FROM TC4 TO TC1 TABLE ...........................................41

FIGURE 17. MOTION OF PALLET FROM TC1 TO RLT TABLE (RAISE)..............................41

FIGURE 18. MOTION OF PALLET FROM RAISED TC1 TO RLT TABLE ..............................42

viii
 CHAPTER ONE

INTRODUCTION
1.1 Background

Manufacturing deals with the conversion of raw materials to finished materials or

products. The main components of manufacturing process are: business activities,

product design, production planning, and production. Business activities deal with

sales and marketing, product design concerns with the development of the product

according to the specifications of the customer. Production planning and production

control the generation of the product.

Automation has brought several drastic changes in manufacturing over the past

century. These changes include increase in overall productivity and profitability of a

manufacturing system. Development of electronics (transistors and micro chips) led to

a jump in control technology and precision of various instruments. This laid a path for

efficient and cost effective manufacturing processes. The definitions of automation

given by various prominent persons are:

1) ‘Automation is the automatic handling of parts between progressive

production methods from the stand-point that we must consider the effects of

automatic handling on each and every phase of our manufacturing processes’

[1].

1
 2) ‘Any continuous and integrated operation of a production system that uses

electronic or other equipment to regulate and coordinate the quantity and

quality of production could be termed as automation’ [2].

Automation of manufacturing systems requires integration of various fields such as

mechanical, control and electronic systems, and computers as shown in Figure 1.

Automation in various forms constitutes the backbone of most major industries. It has

become a significant part of defense, medical, aerospace and automotive industries,

materials processing and handling, manufacturing, and consumer products to meet the

increasing demand for the production volume and product variety.

Material handling is an important part of production. Flow of materials in a production

system effects the total time taken for producing the complete manufactured product.

Different types of material handling systems exist for ease of movement of materials

Figure 1. Conjunction of different systems.

2
on the shop floor. They are listed in Table 1.

Autonomous material handling system has both decision-making and reactive

components. The architecture consists of three levels as shown in the Figure 2. At the

lowest level the environment interacts with the system. Next level includes the

proximity or optical sensors, to perceive the environment to give input to the next

higher level and the different actuators that control the output. The role of the decision

and execution level is to control the execution of the program in the memory of the

central processing unit (CPU)

1.2 Problem statement and approach

When a material handling system is to be made autonomous there is a need for additional

sensors and appropriate control logic to manage the discrete events. It should be also

noted that an autonomous system does not differ much structurally from the existing

system. This reduces the overall cost for the automation. Even before the system is built,

modeling and simulation of the system gives not only a good perception of the dynamic

Table 1. Types of material handling systems

Load Type Weight Handling Type

Range
Packages, Cartons, 10Kgs- Flat/tilt belt or gravity roller, ball tables
Plastic Bins 30Kgs
Airport baggage 20Kgs- Close pitched rollers, conveyors, inclined
and parcels 45Kgs carousel
Machine pallet and More than Powered roller, twin stranded chains, walking
special pallet 1500Kgs beam chains, AGV, powered cars, stacker
cranes and racking, lift trucks, cranes,

3
 Decision and Execution
Level
Actions
& State Requests

Sensor and Actuator

Control Perception

Environment

Figure 2. Autonomous system

operations, but also a method to verify the design. An autonomous material handling

system can be modeled as discrete event system at a certain level of abstraction.

1.3 Discrete event system

A discrete- event system (DES) is a set of sequences of events that describe the

behavior of a physical process. A change in the system’s state of the process is

precipitated by the occurrence of an action or event and is not time-driven. DES

represents many important engineering systems such as: communication/computer

networks, manufacturing systems, and transportation systems. State variables in such

systems change their values only at discrete instants of time, and more importantly

such changes are driven by occurrences of discrete-events or by executions of

operation rules. For example, the number of users logging in to a particular computer

network remains the same unless a user logs off or a new user logs on (which are

random events). Another example is the execution of an ordered sequence of actions

4
in a integrated circuit fabrication facility. Discrete event systems also arise naturally in

supervisory-level control of complex systems where discrete decisions are made.

Discrete event systems can be complex, stochastic, hierarchical, and nonlinear.

The control community increased their attention to discrete event systems in the late

1970s and early 1980s, when there was need to develop new methods to solve

practical problems in a number of areas such as automated manufacturing systems,

control of finite-state automata, and verification of logical designs. Surveys of the

early developments can be found in research papers in [4]. DES’s were soon

recognized as a new breed of dynamic systems that are structurally different from the

conventional models characterized by ordinary differential equations. Over the past

two decades, the proliferation of computer technology, the needs for agile

manufacturing, and the rapid growth of communication networks have fueled the

research activities in this important field [5].

Ramadge and Wonham developed the framework for modeling the discrete-event

systems [6]. Several works based upon the supervisory control theory address the

control of discrete event systems [6] and various notions of state estimation under

partial observations were first developed in [7]. Work has been done on all major

branches of DES ranging from logical control to time-based analysis, from

deterministic settings to stochastic frameworks, and from analytical methods to

simulation based approaches. A discrete-event control problem arises when we want

to restrict the system to perform a specified subset of overall system behavior. A

solution to the discrete-event control problem exists when we construct an overseer

5
(or supervisor) to achieve the desirable (or legal) behavior by either preventing some

events from taking place (disabling an event) or allowing – but not forcing –others to

occur (enabling an event) [8].

1.4 Outline
This work begins with the procedure for developing a machine design concept. It

describes the various steps involved, to design an automated system and its

components such as actuators, controllers, and sensors in Chapter 2. The following

chapter gives a detailed illustration of the present working system and its design

problem. Chapter 4 gives the detailed information regarding various design changes

proposed and the methodology used to simulate the system. The results and summary

are discussed in Chapters 5 & 6 respectively.

6
 CHAPTER TWO

BASIC AUTOMATION DESIGN CONCEPT

2.1 Overview
The design and development of any product must have a predetermined path to

achieve its desired objectives. The predetermined path for the design and development

of the product is in no way applicable to all designs, but some general rules and

guidelines are typically found in any design methodology. Although many authors

have various well-documented design methodologies, no particular methodology is

all-inclusive for all designs, but a typical design has the following steps:

Step 1: The designer requires product specifications, and technical information from

the customer. Basic information required to develop a machine concept includes

machine specifications, required performance, and customer unique specifications,

such as in house standards, drawings of product assemblies and components, which

the machine will have to handle, or otherwise interface/interact with.

Step 2: The process or machine requirements are to be defined on the basis of

customer information.

Step 3: Identify alternative methods to mechanize process operations identified above.

Before looking for an alternative design the designer has to have complete

understanding of the requirements of the present systems in order to incorporate the

best of the alternative designs into one.

7
Step 4: Synthesize system concept(s) to fulfill process requirements with identified

mechanizations, using designer creativity and experience with similar kinds of

systems. Steps 1-3 of the concept design process have resulted in identifying the

system elements with which we have to work.

Step 5: With proven technology, available components and designer experience,

evaluate alternative machine concepts technically. Modeling, simulation and value

analysis of the system could help the designer to evaluate his conceptual design.

Step 6: The design has to be finalized on the basis of customer budget and

requirements along with consistency, maintenance, and availability of spare parts.

Step 7: Detailed Design consists of:

• Prepare individual detail drawings for all fabricated machine parts.

• Perform tolerance study to assure proper machine references, alignments, and

clearances.

• Calculate stresses in machine members, holding brackets, pressure vessels,

etc., and select material and size members.

• Write control programs (algorithms) if computer controlled.

• Document of operational procedures and troubleshooting of machine

8
Step 8: Procurement of the materials as per the design specifications and to build the

system with the assembly of various parts. Lots of interaction with the customer has to

take place between detailed design and this step.

Step 9: Test the system. First the system is tested to meet the structural requirements

and then a functionality test is performed to verify whether system meets the

requirements of the customer.

2.2 Breakdown of the design into components

2.2.1 Actuators and drive systems

Actuators are the means by which parts are moved. They act like muscles giving

power to the system. Actuators are classified as hydraulic, pneumatic and electrical

according to the type of energy they use to drive the system. Hydraulic and pneumatic

are fluid actuators where power is carried by oil or by air respectively. They different

types of actuators, their advantages and disadvantages are listed in Table 2.

2.2.1.1 Pneumatic cylinders

These are popular actuators for use in automatic machinery applications. As industrial

facilities have easily available compressed air at pressures 80-100 psi, while low-pressure

air can be exhausted to environment without posing any safety or environmental hazard.

The fundamental application of a cylinder is to exert a linear force through a distance

known as the cylinder stroke. A pneumatic cylinder exerts a non-uniform force over the

extent of its stroke. This is due to the compressibility of air. The criteria for selecting

9
 Table 2. Types of actuators

Type Description Advantages Disadvantages

Hydraulic Motion generated by High power to Leakage problems

liquid present in the weight ratio, high and expensive. The
system. Liquid is acceleration can working fluid usually
typically oil or water be realized. organic compound
based. possesses safety
problems (such as
inflammability) in
hazardous locations.
Pneumatic Motion generated by Lower cost, good Analog control of
compressed gas, usually for open-close position is difficult.
air. applications, that
is for discrete
control.
Electric Motion generated by Good speed These are more
electrical power with control reliable, expensive than
magnetic flux and readily pneumatic actuators
interacting with available power but lower in cost
electrical current flow. source. compared to
hydraulic actuators.
Easier to maintain.

10
a pneumatic cylinder for machine application are: force, stroke, speed, cylinder

configuration, and mounting.

2.2.1.2 Cylinder force requirements

Having defined the force requirements from the conceptual design the minimum

cylinder diameter can be selected by:

4F
D=
πP

where, D= Diameter capable of providing required force

F= Maximum force required to be exerted by actuator, including the force to

overcome the start the load in motion.

P= Pressure of the air supplied to the cylinder

2.2.2 Controller systems

The controller system will ultimately control the mechanical device and has a great

impact upon the overall performance and reliability of the machine. In fact the

controller can “make or break” a design.

The types of controller systems are listed in Table 3.

2.2.2.1 Basic structure of programmable controller system

The general structure of a programmable controller system is illustrated in Figure 3.

These functions communicate with each other and with the signals of the

machine/process to be controlled.

11
 Table 3. Types of controller systems

Type of Controller Principle and Advantages Disadvantages

System Characteristics
Relay Control Control relays are Very cheap and Cannot perform
used to implement simple in logic complex tasks
sequential machine for small tasks and not flexible.
control. like building Wiring is
lighting or alarm expensive.
systems
Programmable The PLC They are very Multiple
Logic Controller environment allows well established controllers are
(PLC) for I/O cards, for industrial required for
motion control applications. controlling
cards, etc. different systems.
Industrial Primary function Highly versatile, The software can
Microcomputer (PC would be motion easy to be overly
Based) control and implement. complex.
secondary function
as logic controller.
The architecture
includes ISA,
EISA, and PCI
standard PC bus
structures.
Integrated Industrial They architecture is These are User has to
Modules (Bus or modular. The back extremely integrate the
LAN architecture) plane of the bus versatile. They system. Thus user
architecture has a minimize the needs to have a
very high data computation good knowledge
transfer rate, which requirements of the modules.
is suited for high due to modular The module cards
data transferal in structure, thus are expensive.
applications. In reducing the
LAN the cost.
communication is
done through
ethernet or fiber
optic.

12
 Figure 3. Basic functional structure of PLC

2.2.2.2 Programming of PLC

All controllers have to be programmed to meet the functions of the system. A control

program is made up of:

Functions: Standard functions such as ADD (addition), ABS (absolute value), SQRT,

SIN (sine), COS (cosine) and Boolean functions like NOT, AND, OR and

combinations of Boolean functions are universal in nature. User defined functions,

once defined, can be used repeatedly.

13
Function Blocks, FBs: Function Blocks are the equivalent to Integrated Circuits, ICs,

representing a specialized control function. They contain data as well as the algorithm,

so they can keep track of the past (which is one of the differences with respect to

functions). They have a well-defined interfaces and hidden internal logic, like an IC or

black box such as temperature loop control, and PID control. Once defined, it can be

used repeatedly, in the same program, different programs, or even different projects.

This makes them highly usable. Function blocks can be written in any of the

International Electro technical Commission (IEC) languages (ladder logic, instruction

list, functional block diagram, structured text), and in most cases even in “C”.

Sequential flow-charts (SFC): SFC describes graphically the sequential behavior of a

control program. It is derived form Petri Nets and IEC 848 Grafcet, with the changes

necessary to convert the representation from documentation standard to a set of

execution control elements. SFC consists of Steps, Linked with Action Blocks and

Transitions. Each step represents a condition, which, when true, causes the step before

the transition to be deactivated, and the next step to be activated. Steps are linked to

action blocks, performing a certain control action. Each element can be programmed

in any of the IEC languages, including SFC itself. One can use alternative sequences

and even parallel sequences, such as commonly required in batch applications.

Programming Languages: IEC has defined four programming languages. This means

that their syntax and semantics have been defined, leaving no room for dialects. The

languages consists of two textual and two graphical version:

Textual languages are instruction list and structured text.

14
 1) Instruction List (IL): Instruction List is a textual language. It resembles

assembler.

2) Structured Text (ST): It is a powerful high-level language with its roots in

Ada, Pascal and “C”. It contains all the essential elements of a modern

programming language, including selection branches (IF-THEN-ELSE and

CASE OF) and iteration loops (FOR, WHILE and REPEAT). These elements

can also be nested. It can be used excellently for the definition of complex

function blocks, which can be used within any of the other languages.

Graphical languages are ladder diagram and functional block diagram.

1) Ladder Diagram (LD): It is based on the graphical presentation of relay ladder

logic. The symbols are similar to electrical circuit.

2) Function Block Diagram (FBD): Function Block Diagram is very common to

the process industry. It expresses the behavior of functions, function blocks

and programs, as a set of interconnected graphical blocks, like electronic

circuit diagrams. It looks at a system in terms of the flow of signals between

processing elements [9].

2.2.3 Sensors

Sensors are devices through which a system is able to perceive its environment. They

are an important component of an automated system. They are of different types,

classified according to their application or according to the approach of measuring

data from the working environment. There are different technologies employed in

15
sensing schemes- contact closure, magnetic, piezoelectric, capacitive, photoelectric,

magneto resistive, piezoresistive, ultrasonic, acoustic.

Types of sensors or sensing equipment according to the approach of measuring data

from the working environment:

1) Contact Sensors- These sensors interact with the surroundings at the work

place or with the job being performed to make their measurements or to

get data about the job. The following are the types of sensors that are

usually used as contact sensors:

i) Micro switch. This is the simplest form of contact sensors.

Micro switch provides with a simple binary output (0 or 1)

representing the presence or absence of an object. The control

of applied forces and accurate positioning of switch is difficult

due to the inertia of moving parts; but they can be used for

supervising static states like door or valve positions, start/stop

positions.

ii) Tactile Array sensors. These sensors are mostly used in mobile

robots and automated guided vehicles (AGVs) to provide a last

resort indication of collisions with surrounding obstructions.

2) Non-Contact Sensors. These sensors are preferred over contact sensors

when sensors cannot be in physical contact with the job. This can be

due to various engineering considerations, like blocking of the process

16
 of job execution (especially in continuously flowing process) or the

nature of the sensor is that it does not need contact at all. The following

are frequently used non-contact sensors:

i) Acoustic sensors. These are used to sense over long ranges for

various objects. The principle is similar to the hearing

phenomenon in bats.

ii) Proximity sensors. These sensors detect an object when it is at

a certain distance. Table 4 gives the common types of

proximity sensors.

iii) Optical sensors. They work on the principle, interrupt a light

beam by a work piece or machine element or reflect a light

beam back by the work piece or machine element passing in

front of the projected beam. The reflection can be direct scan,

reflective scan, and retro reflective scan. For example,

photoelectric sensors, optical time-of-flight sensors, vision

sensors, and rotary position encoders.

Sensors can also be classified on the basis of application or on the basis of the physical

property they sense or measure. For example: temperature sensor, pressure sensor,

flow monitors, level sensors, densitometer, range sensors, speed, orientation, and

position. Sensors measure the property using one or more principles mentioned above.

17
 Table 4. Types of proximity sensors

Type of Description
proximity
sensor
Inductive They are designed to operate by generating an electromagnetic
field and detecting the eddy current losses generated when ferrous
and nonferrous metal target objects enter the field. The sensor
consists of a coil on a ferrite core, an oscillator, a trigger-signal
level detector and an output circuit. As the metallic object
advances into the field, eddy currents are induced in the target. The
detector circuit then recognizes the decrease in the amplitude and
generates a signal. Care should be taken that vibration the objects
is less than the hysteresis band/differential travel to avoid
chattering of the sensor.
Ultrasonic They operate by emitting and receiving bursts of high-frequency
sound waves. They are usually in the order of 200kHz. There are
two basic modes of operation: opposed mode and diffuse (echo)
mode. These have inherent blind zone located in the sensing face.
They cannot detect the object if it is in the blind zone.
Capacitive These are designed to operate by generating an electrostatic field
and then detect the changes in this field when target approaches the
sensing face. It consists of a capacitive probe, an oscillator, a signal
rectifier, a filter circuit and an output circuit. The approach of the
target raises the capacitance of the probe. When the capacitance
reaches the threshold, oscillator is activated, which triggers the
output

18
 CHAPTER THREE

EXISTING DESIGN AND ANALYSIS

3.1 Introduction
General Electric Co. has a manufacturing facility in Maryville, Tennessee. The blank

cutting machine is a critical component of the whole facility. It provides the sheet

metal for the appliances developed by the plant. As a part of the undergoing

automation, The Providence Group (TPG), Applied Technology was awarded the

contract to develop an automated material-handling system (shown in Figure 4.) for

offloading the loaded pallets (weighing about 6000lbs when fully loaded) arriving

from the blank cutting machine. The material handling system should finally send the

emptied pallets to the blank cutting machine after being unloaded by a forklift.

Figure 4. Complete material handling system

19
The whole system was developed, tested and delivered by TPG. The system is mainly

comprised of four tables, two optical sensors, and a proximity sensor on each of the

four tables. The primary set up of the system is shown in Figure 5. The Figure 5

shows four tables TC1, TC2, TC3, and TC4 that constitute the material handling

system that was built, while the roller lift table (RLT) is a part of the blank cutting

machine. The four tables are much lower in height compared to the elevation of the

RLT. The TC1-A, TC2-A, TC3-A, and TC4-A are proximity (inductive) sensors,

while TC1-B, and TC3-B are optical (retro reflective) sensors. The arrows show the

direction of flow of pallets. The rollers at the boundary of the system restrict the pallet

from moving in any other direction. The whole system is controlled with a

Programmable Logic Controller (PLC), while the blank cutting machine runs on a

separate PLC.

3.2 Primary function of the system

The moving rollers on the RLT push the loaded pallet towards table TC1. Table TC1

has to be in raised position with the chains moving forward in the direction of table

TC2 during the arrival of pallet from RLT. When the proximity sensor TC1-A senses

the presence of pallet the table is lowered and is pushed towards table TC2 if the table

is empty. Then the loaded pallet is pushed towards table TC3 and where it is

unloaded. After it is unloaded, the pallet is pushed towards table TC4. The pallet is

pushed from TC4 to TC1 if and only if RLT is empty. Sensor TC1-B cannot sense the

20
 Figure 5. Present system layout

presence of a pallet but it can only sense the passing of pallet. The structural

hindrances on the RLT are the cause for this phenomenon. The operator should have

the flexibility to run the system in manual or automatic mode. He should have the

capability of an emergency stop, and alarm buzzer to acknowledge the emergency

situation. The material handling system should send a command to the blank cutting

machine before pushing the pallet towards RLT for the blank cutting system to start

the motion of its rollers.

21
3.3 Detailed system description
3.3.1 Actuators

Rodless pneumatic cylinders are used for the moving the pallets over the tables. The

bore is 60mm and the stroke lengths are equal to the distance they move the pallet

over the table, which is 60” for table TC2 while 48” for tables TC3 and TC4.

3.3.2 Sensors

Four proximity sensors and two optical sensors are positioned on the tables as shown

in the Figure 5. Proximity sensors are inductive in nature while optical sensors are

retro reflective.

3.3.3 Tables

Table TC1 has different configuration compared to the rest of the three tables TC2,

TC3, and TC4. It has two axis of motion; in one axis it has chains driven by an electric

motor and has rollers to support the movement of pallet in the other axis. This table

was bought from Allied Technologies. It was designed to lift itself to the same height

as the RLT. The rest of the three have gravity conveyor rails on the border and ball-

transfer conveyor rails as the floor of the tables for the ease of motion of the pallet.

Pictures of the tables can be seen in Figures 6 & 7.

3.3.4 Control system

The control system comprises of a micro controller from GE Fanuc, which has the

capacity of 16 DC inputs, 1 DC output, 11 relay outputs and power supply. A micro

22
 Chains

Roller

Figure 6. Table TC1

Gravity
Rollers

Pneumatic
Cylinder Support
Rollers

Figure 7. Tables TC2, TC3, TC4

23
controller extension (with eight DC inputs six-relay outputs and power supply) was

also included to facilitate the required functioning of the system. The programming of

the PLC was done based on ladder logic. The system works in both automatic and

manual mode. Even in the manual mode, all the commands go through the logic and

software interlocks for the safety of the system. The following are the external

switches for the system:

1) 3- position selector switch for manual, automatic and off mode.

2) Six push button switches (for manual operation) for commanding the

pallet to move from one table to another.

3) 3- position selector switch for selecting the number of pallets in the

system.

4) One emergency push button.

5) One alarm buzzer.

3.3.5 Working principle

The motion of the pallet from TC1 to RLT and TC1 to TC2 occurs by the movement

of the chains on the table. The motion from TC1 to RLT occurs when the table is the

up position while the motion from TC1 to TC2 occurs when the table is in down

position. The motion of cylinders controls the movement of load from TC2 to TC3,

TC3 to TC4 and TC4 toTC1 (the cylinders on the earlier table controls the motion

24
onto the next table). In the manual mode, commands for the movement of the pallet

are accepted from the operator, but the command is executed only if the criteria for the

movement of pallet are met. The system disregards the command until the various

other rules are cleared.

In the automatic mode the system decides which cylinder has to be moved in the

correct direction for the motion of pallet using the signal inputs from various sensors

located on the peripheral of the table.

In any mode (manual/automatic) the motion from the RLT towards the table number

1(TC1) occurs automatically after the cutting of the sheets is completed. As the loaded

pallet comes towards TC1 the sensor TC1-B acknowledges the pallet, which makes

the chains on the TC1 to move in the direction of TC2. As soon as the pallet is

completely on TC1, the sensor TC1-A stops the motion of the chain.

The movement of the pallet from TC1 towards TC2 is started when there is a load on

TC1 and TC2 is empty (sensed by the sensor TC2-A). As soon as this condition is

satisfied the chains push the loaded pallet towards TC2 and are stopped by the sensor

TC2-A. In any mode for the motion of the pallet TC2 towards TC3, TC3 table should

not have any pallet. The motion from TC3 towards TC4 is started only after the load

on pallet is removed when the pallet is on TC3. The sensor TC3-B checks whether the

load is removed, sensor TC4-A checks whether the table TC4 is empty or not, only

25
after which the process is initiated. The loaded is pushed from TC4 to TC1 only if

there is no pallet on TC1 (sensed by TC1-A) and there is no pallet in RLT. This

process is done using sensor TC1-B and the logic of the program. The pallet moves

onto TC1 when the table is in the lower position. The chains are not active, but the

rollers on TC1 aid the motion.

After the system was built at TPG, Applied Technology and delivered to the customer,

the customer experienced the following faults in the system due to low interaction of

the controller with the mechanical components of the system. The major faults were,

1) PLC was locked in a state of confusion (jammed) when any of the

proximity/optical sensors were accidentally activated by human/machine

interference. This was mainly due to various timers used in the ladder logic

and the commands to the actuators were interlocked with different stages

of the program. The sensors ware not positioned appropriately.

2) The pallet was bouncing from gravity conveyor rollers during its traverse

from table to table.

3) Active sensors for cylinder stroke were absent; hence the controller was

ignorant of the exact position of the cylinder.

26
4) Oblique movement of the pallet occurred during its travel from table to

table. The design of the cylinder pusher was such that the force applied on

the pallet was not distributed along the face of the pallet.

27
 CHAPTER FOUR

IMPROVED DESIGN AND ANALYSIS

4.1 Revised design
In engineering scenarios, the designer has the ultimate responsibility to make

decisions, which define the basic characteristics of the system. Based on the

designer’s experience, advice from manufacturers and customer requirements, the

previous design was modified to incorporate:

• The cylinders have proximity switches at the beginning and end of the stroke.

• The shape of the pusher is altered so that the force is applied at two

symmetrical places on the pallet. Guide rails are added on tables TC1 and TC2

to avoid zigzag motion of pallet and shock absorbers on TC2 to avoid

bouncing of the pallet.

• Limit switches are added for the up and down movement of the table TC1

• The whole of program is rewritten so as to meet the discrete event system

criteria (each event is independent of other and determined by its sensors),

avoiding timers and to make the system intelligent.

4.2 Structural
The proposed system consists of two shock absorbers, the same pneumatic cylinders

with proximity switches at the end of each stroke and two limit switches to recognize

28
the up and down position of the table TC1. The entire system can be run in both

automatic and manual mode. The position of the sensors on the tables is shown in

Figure 8.

The position of sensors TC2-A, TC3-A, TC4-A is to be altered so that they are

activated only when the pallet reaches the end position. The proximity switches at the

beginning and ending of the strokes of cylinders provide active feedback. These

switches help the cylinder to hold in the fully extended position for a few seconds so

that the pallet is pressed against the boundary, avoiding bouncing back. Since table

TC1 does not has a pneumatic cylinder, shock absorbers are added on table TC2 so

that the pallet does not bounce during the travel from table TC1 to TC2.

The addition of guide rails on tables TC1 and TC2 in the proposed systems aids the

pallet to move in a straight path. The proposed structural change in the push rod of the

cylinder also aids the above objective. The shock absorbers on table TC2 avoid

bouncing of the pallet from the guide rails along the boundary of the table.

4.3 Programming
A manufacturing process can be viewed as a sequence of discrete events. These events

are a result of characteristics inherent in such systems as job shops, flow shops or

flexible manufacturing systems. In typical time history of events, more than one event

can occur at the same time, the time intervals between events are usually different

29
 T RLT Table (Loading area)
C
3
- TC1-B
B

TC4-A

TC4 TC1

TC1-A

TC3 (Unloading area) TC2

TC2-A

T
C
3 Guides Shock absorbers
-
A

Figure 8. Proposed system

30
such that it is possible for one event to trigger a series of events and cause the system

operations to take place simultaneously (concurrency or parallelism) or

asynchronously. In the case of inappropriate event triggering, system operations may

cause a deadlock or conflict. The stage programming method helps to avoid deadlock

in a discrete event control system. This method can reduce programming time by up to

70% and also drastically reduce the troubleshooting time by up to 85% [11]. Stage

programming breaks a program into logical stages, making complex systems design

easier. The stages can be programmed individually without concern for how they will

affect the rest of the program. At each stage, all the output actuators are dependent on

the status of input sensors and they can be easily identified and programmed. The

concept of independent I/O combination logic between stages simplifies the

interlocking programming process of a complex logic diagram. Output of every

actuator is a function of all the inputs from the sensors, which affect the actuator.

The movement of the pallet from one table to another is considered as a single event.

To determine the state of the system, sensors are placed to track the events they react

to, and to events they generate. Each event is controlled by logic, which is dependent

on the table sensors. This type of dependence suggests stage programming. When all

the interlocks for the movement of pallet are satisfied, the logic gives a command to

the actuator on that table to move the pallet. This makes the system mechanically

more robust than the previous system.

31
4.4 Summary of logic complexity
The program to control the system used number of basic Boolean gates. Table 5 gives

a detailed list of number of inputs, outputs and major logic blocks used. Item 6 in

Table 5 includes various blocks required for the control of the simulation, performed

to verify the control logic. This is discussed in section 5.3 and 5.4 along with the

conditions under which the simulation was executed.

Table 5. Control system complexity

S. No Description Number
1 Inputs 23
2 Outputs 9
Major Logic Blocks
1 AND 114
2 OR 16
3 Flip-flop 38
4 Timers 5
5 Counters 4
6 Other blocks 134

32
 CHAPTER FIVE

IMPROVED DESIGN AND PERFORMANCE

5.1 Hardware setup
The PLC hardware consists of the power supply, the central processing unit (CPU),

the communication processor (CP), a 32-channel digital input module, and a 16-

channel digital output module. The model of CPU and CP is 416-2 (DP) and CP443-1

respectively. All are mounted on an active back plane bus. This system communicates

with the computer (Programming Device) through an Industrial Ethernet link.

5.2 Software setup

Siemen’s software PCS-7 (Process Control System 7) and WinCC (Windows Control

Center 5.0) are used to simulate the system. PCS-7 is the resident software in which

PLC logic can be programmed using all four IEC languages stated in section 2.2.2.2.

FBD programming language was used to develop the logic of the system.

WinCC is the software to develop graphical interface between the user and PCS-7. It

helps the operator/user to have real-time control on the system. The graphical interface

can in fact give commands to the system, and display data from the system. It helps

the operator/user to monitor the system constantly. Each element in the human

machine interface (HMI) is made real-time by tagging them to their respective

input/output (I/O) blocks in the logic.

33
5.3 Simulation
The graphical screen, which controls the whole system, can be seen in Figure 9. The

sensors and actuators are represented graphically on the screen. An HMI button is

provided on the screen to initiate simulation. When this button is made active by

clicking the mouse on its icon, control inputs to the PLC logic are shifted from the

real-world field I/Os to the simulated screen inputs. In this simulation mode, clicking

on a sensor will toggle the simulated input of that particular sensor to the PLC logic.

The top and side view can be seen in the Figure 9.

The improvised system with additional sensors and structural changes is simulated

with the setup mentioned in section 5.1. The aim of the simulation is to depict the

Figure 9. Initial setup of the simulation

34
response of the system to various field conditions. The system is simulated with a

slight level of abstraction. The following are the limitations of the system:

1) The logic developed is independent of the number of pallets in the system (not

exceeding three). But at the start of the simulation we need to input the number

of pallets to be simulated.

2) All the proximity and optical sensors, and limit switches are to be activated by

clicking the computer mouse on their respective screen icons.

3) A “Start” command has to be issued by clicking on the “Start” HMI button on

the screen. This initiates the automatic function logic.

4) When the system starts in the automatic mode, there should be no pallet on the

RLT table. If a pallet is present on that table, the system should start in manual

mode and then the system should change into automatic mode. This is exactly

not a limitation of the simulation as even the actual system has been

programmed to meet this criterion. This gives the controller a start position.

5) The shock absorbers are not shown in the simulation.

The above stated limitations create a small difference between the simulated and the

real-world systems, but it helps us understand the reaction of the proposed system to

real-time problems.

35
The following are the evaluation criteria performed in order to meet the requirements

of a robust system.

1) The movement of pallets on the tables, regardless of the number of pallets in

the system.

2) Response of the system when emergency stop is pressed under various

conditions of motion.

3) Discrete control of each event (motion of pallet from one table to another).

4) To verify that system logic can prevent the system from a “grid-lock” in the

incidence of inadvertent activation of a sensor, or a sensor malfunction.

5) To verify intelligent decisions by the controller regarding movement of pallet

from TC1, thereby avoiding gridlock.

6) To verify that system logic will take appropriate action to avoid gridlock due

to movement interruptions caused by mechanical problems such as jamming

etc.

5.4 System states

During the execution of simulation various screen shots have been taken to give a

clear picture of how the system responds. Pictures of system state are included in this

section to give a clear idea of the sensors are active and which sensors to be inactive

36
for a particular event to take place. All the sensors and commands active are shown

green and the inactive ones are shown as red.

During the motion of pallet from RLT to TC1 sensor TC1-B is activated. The table

TC1 is in raised position. After the pallet is completely on TC1 than table TC1 is

lowered until the low limit switch is hit. This stops the lowering of the table and than

the event RLT to TC1 is complete. This is shown in Figures 10 and 11. Now the

controller verifies whether a pallet is present on TC2 or not. If and only if there is no

pallet on TC2 (sensed by TC2-A) and there is a pallet on TC1 (sensed by TC1- A),

which has arrived from the RLT (sensed by TC1-B) and TC2 cylinder is at home

position (sensed by the proximity switch at the beginning of the stroke of cylinder)

does the event TC1 to TC2 is enabled. If the system is in auto mode it immediately

activates that event and if it is in manual mode it waits till the manual command is

given from the panel. When all these conditions are satisfied TC1 to TC2 motion is

executed with guides raised. This is depicted in Figure 12.

Similar interlocks are present for the motion of pallet from TC2 to TC3 and other

events. This is represented in Figures 13, 14, 15, 16, 17, 18, 19 and 20.

37
Figure 10. The state of system during motion of pallet from RLT to TC1

Figure 11. Downward motion of pallet during RLT to TC1 table

38
Figure 12. Motion of pallet from TC1 to TC2 table

Figure 13. Motion pallet from TC2 to TC3 table

39
Figure 14. State of sensors when loaded pallet is present on TC3 table

Figure 15. Motion of pallet from TC3 to TC4 table

40
 Figure 16. Motion of pallet from TC4 to TC1 table

Figure 17. Motion of pallet from TC1 to RLT table (raise)

41
Figure 18. Motion of pallet from raised TC1 to RLT table

42
 CHAPTER SIX

CONCLUSION AND FUTURE WORK

6.1 Summary
The improved design and simulation of automated material handling system is the

culmination of over 18 months of research at TPGAT. To improve the present system,

all the problems in the system were studied and analyzed. A new system with better

controller and structural changes is thus proposed.

The proposed system mainly solved two significant issues: blocking and deadlock.

These problems exist in the present system primarily due to insufficient sensors. Also,

the logic of the controller was based on timers that were activated/deactivated as soon

as their preset limit of time ended. This occurrence of events independent of the

position of the cylinder/actuator causes deadlock. Hence a discrete event system

philosophy has been suggested to handle this issue.

A well-simulated model provides a good path to build the improved system.

Simulations were performed under various real-time situations such as deadlock,

jamming, accidental activation of sensors and faulty sensor. These simulations

indicate that the proposed system is more robust and autonomous. They also help us to

conclude that the improved system will be able to meet the requirements safely.

43
The simulation covers most practical aspects and suggests that the improved design

can be implemented with little cost impact.

6.2 Future trends

An immediate research topic that arises is the formulation of the analytical model of

the system. This will lead to an improved simulation that is closer to the real-world

system. The system can be modeled as closed cyclic queuing process with loading and

unloading tables as serving stations with the intermittent tables as waiting stations. To

model the system cyclic queuing process, the serving time for loading and unloading

has to be computed using empirical data from present system.

In addition, further research may explore the possibility of a more optimized system.

In order to minimize the travel time for a pallet to complete a cycle, the relation

between the numbers of pallets and tables has to be developed. This will help the

engineer to decide upon the number of pallets that can exist in a given number of

tables and improve the performance of the material handling system.

44
BIBILOGRAPHY

45
[1] William C. Leone, “Production Automation and Numerical Control”, The Ronald

Press Co., 1967. pp. 3-4.

[2] Walter Buckingham, “Automation, Its Impact on Business and People”, New

York: The New American Library on World Literature, Inc. 1961. p. 15.

[3] N. Vishwanadham, “The Past, Present, Future of Supply Chain Automation”,

IEEE Robotics & Automation Magazine, June 2002. pp. 48-56

[4] Cassandras C. G., and Lafortune S., “Introduction to Discrete Event Systems,”

Boston, Kluwer Publisher, 1999, p. 848.

[5] Y. C. Ho, “Discrete Event Systems: Analyzing Complexity and Performance in

the Modern World,” New York, IEEE Press, 1991. p.650.

[6] P. J. Ramadge and W. M. Wonham, “ Supervisory Control of a Class of Discrete

Event Processes,” SIAM Journal of Control Optimization, Vol. 25, no.1, 1987, pp.

206-230.

[7] C. M. Ozveren and A. S. Willsky, “ Observability of Discrete Event Dynamical

Systems,” IEEE Transactions of Automatic Control, Vol. 35, July 1990, pp.797-806.

[8] S. Laurie Ricker, and Karen Rudie, “Know Means No: Incorporating Knowledge

into Discrete-Event Control System”, IEEE Transactions on Automatic Control, Vol.

45, No. 9, September 2000, pp 1656-1668.

46
[9] http://www.plcopen.org, source for industrial standards for PLC.

[10] Personal Conversation with Mr. Ajit Deobhakta, The Providence Group Applied

Technology. Spring 2002.

[11] Shih Sen Peng and Meng Chu Zhou, “Sensor-Based Petri Net Modeling for PLC

Stage Programming of Discrete-Event Control Design”, Proceedings of IEEE

International Conference on Robotics and Automation, 2002, Washington, DC.

May2002

[12] J. Stevenson, “Fundamentals of PLCs, Sensor and Communication”, 2nd Edition.

Prentice Hall. 1999. pp. 145-150.

[13] Kendrick W. Lentz, Jr., “Design of Automatic Machinery”, Van Nostrand

Reihold Co. Ltd. 1985. pp. 129-132.

[14] T. Samad, J. Weyrauch, “Automation, Control, and Complexity”, John Wiley &

Sons, Ltd. 2000. pp. 3-8.

[15] E. W. Kamen, “ Introduction to Controls and Manufacturing”, Academic Press.

1999. pp. 4-6.

[16] T. Tolio, S. B. Gershwin, “ Throughput Estimation in Cyclic Queuing Networks

with Blocking”, Analysis of Operation Research, 1998. pp.207-229.

47
APPENDICES

48
Appendix A. Description of FBD programming

49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
Appendix B. Description of Function Block CHDI

82
83
 VITA
Siva Kali Prasad Dasari was born at Tuni, Andhra Pradesh in India on May 13, 1979.

He was raised in Visakhapatnam and went to grade and junior school at Timpany

School. He graduated from Bharatiya Vidya Kendra Junior College in June 1997.

From there he went to Regional Institute of Technology, Jamshedpur and received his

B.S. (Eng.) in Mechanical Engineering in June 2001.

After completing his undergraduate career, he decided that he would continue his

education pursuing Master of Science in Mechanical Engineering at University of

Tennessee, Knoxville.

84