I.

Grand merci
II. Introduction
III. Principle of function

PART I : FEEDING AND CLASSIFYING MACHINE

IV. Principle of function

V. Machine elements
V.1. Slide
V.2. Belt
V.3. Coupling
V.4. Pillow block bearing unit and flange bearing unit
VI. Pneumatic jack

VI.1. Double effect jack

VI.2. Single effect jack

VII. Motor
VIII. Roller
IX. Sensors
IX.1. Photocell sensors
IX.2. Capacitive sensor

PART II : TESTING MACHINE

I. Principle of function
II. Machine elements

III.1. Radial bearing

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 III.2. Axial bearing

III.3. Linear bearing

III.4. Coupling

III.5. Cosinat

PART V: PARTIE RDM CALCULATION FOR ALL PARTS

PART III : LISTE OF FIGURES :

1- Initial Grafcet

2- Initial Grafcet Level 1

3- Normal Production Grafcet 1

4- Normal Production Grafcet 2

5- 2D Elements Drawings

6- Electric Schema and Pneumatique Plan

12- Grafcet

13- LISTING INPUTS / OUTPUTS

14- PROGRAM

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 Grand merci
Le résultat final de tout effort doit être le succès. Ce dernier ne pourrait être
accompli sans la direction et l’aide de nos professeurs qui n’ont appris et nous
ont suivis pas à pas dès le commencement jusqu’ à la derrière minute de notre
parcours

 Ing: Bilal SOUEID

 Mr:Rostom ROSTOM

Ainsi que tous ceux qui ont veillé et surveill é nos travaux afin d’y arriver.

Nous remercions aussi l’école technique supérieure Amlieh qui nous a intégrés
en tant qu’un groupe homogène.

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 Introduction
General Introduction:
The progress of science has broadened man's knowledge of the universe, of
matter, of the life of beings. On the one hand, this knowledge helps man to
improve his life, but one can also wonder, on the other hand, how well he is able
to master the applications of this knowledge.
Let us first observe progress in individual life, the tasks of the daily life of man
and woman have become easier to carry out. Indeed, new household
technologies and machines free the woman and the man from the hard jobs and
the painful tasks that they had to accomplish at home in the factories or was the
necessity of going to the draw of room that is even At the office, the computer is
able to store products and return them as needed, reducing unnecessary effort
and saving time and space for employees.

The Objectives of the Project:

At the end of the Second year TS, students must make a project to test all
that they have learned during these two years.
This year our project was to make an industrial machine, that is capable
of performing a lot of industrial work.

Our machine involves two main parts:

 Mechanical part.
 Electrical Automated Part.

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 Principle of Functioning
The operative part of this machine is formed of two parts:

 Supply and classification of pieces according to their thickness.

 Part for sorting the pieces according to their height and color.

The overall functioning of the machine as follows:

Once a piece is present in the feeding slide a system of SAS makes it possible to
release the piece one by one. Another jack pushes the released piece toward the
main belt which will be identified later by sensors making it possible to identify
Their height as (large, medium and small)

The main belt feeds a trio treadmill room classifies the cylinders according to
their height.

A robot will pick up the pieces one of three and place it on the sorting machine.

The sorting unit consists of 3 stations:

 Feeding

 Testing

 Sorting

Once the parts height is identified by sensors it allows to start the operation of
the the second part of the machine which starts a programmed control that
allows to evacuate The piece to a system of sorting the pieces according to their
material and height

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The sorting system consists of three movements :

 Longitudinal (depending on color and piece material)

 Transversal (team of a jack carrying a suction cup)

 Vertical (Team of one carrying a sucker)

The system is controlled by a programmable Logic controller (delta) equipped

with input and output extensions.

 Double and Single Effect Cylinders

 24V DC Motors

 5/2 Bistable and Monostable Distributors with electropnaumatic effect

 Sensors (captive, inductive, photo electric and magnetic)

 Automatic Control System

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 PART I:
Feeding and
classifying

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 IV. Principle of function of
Machine

From the mechanical point of view, two pneumatic pistons are set in parallel
position 130 mm gap on the feeding slide to pass pieces in order, when the
cylindrical piece slides down, a capacitive sensor detects the cylindrical piece,
a double pneumatic jack push the cylindrical piece on the main-belt, the
main-belt is moved by two rollers, a DC motor delivers a rotational motion
through a coupling connected to the roller belt axe that delivers a
translational motion to the main-belt that guides the cylindrical pieces to
their destination. When the cylindrical piece is pushed to the main-belt, a
guiding device is set to keep the cylindrical piece at the center of the main-
belt, every cylindrical piece has a different height and different material that
is made of (3 types of heights and 2 colors light,dark) but has the same
diameter, when the cylindrical piece passes through the guiding device, three
pneumatic double jack and belts in motion (47 cm separated) are set 90
degrees to the main belt, 3 capacitive sensors are set up in the range of each
pneumatic jack, when the sensor detects the correct height of the cylindrical
piece the pneumatic jack pushes the piece to the belt and rests behind a
triangular shaped flexi preventing the piece from falling and keeps it in the
center till a mechanical sorting takes action.

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V. Machine elements

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 V.1. Slide:__________________________________
This slide is a sheet of steel of 2mm thickness, bending it to a shape of the slide.
It’s fixed to the body of the machine with an adjustable angles, it consist of a
capacitive sensor and two pneumatic pistons set in parallel which regulate the
passing of the cylindrical pieces.

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V.2. Belt:___________________________________
The belts hold the cylindrical pieces on a translational motion to reach to its
destination. The machine consists of a main belt and 3 smaller belts.

It’s made from leather.

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V.3. Coupling:______________________________
The coupling is used to join two axes to transmit a rotational motion.

Unique wrap around Nitrile rubber connecting element, the Snap Wrap coupling
eliminates the need for dismantling the connected equipment, and hence
reduces downtime for maintenance.
Combined with a range of pre-bored hubs, a modular hub design and optionally
spacer elements, the Snap Wrap coupling is unsurpassed for quality, flexibility
and quick installation and easy maintenance.

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V.4. Pillow Block Bearing unit and Flange
Bearing Unit:
Pillow Block Bearing Units and Flange Bearing Units offer a truly cost effective
solution. Ideal for machinery where regular maintenance is required due to the
ingress of dirt for example in agricultural machinery, FS Bearing Units provides a
low cost high quality solution which can represent big savings. FS's low cost -
high quality pedigree means better value for money and a higher profit
potential.
A full range of imperial and metric Bearing Units are available from stock to suit
your requirements, these include:
 Cast Iron Pillow Block Bearing Units
 Cast Iron Flange Bearing Units
(Also available with adaptor Sleeve)
 Cast Iron Flange Cartridge Bearing Units
 Cast Iron Take-up Bearing Units
 Cast Iron Conveyor Belt Tensioner Units
 Cast Iron Cartridge Bearing Units

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VI. Pneumatic pistons

VI.1. Double effect jack:___________________

Air cylinders are pneumatic linear actuators driven by pressure differential in
the cylinder chambers. One side of a piston flange can be pressurized to
provide force and motion with a spring (providing return force after pressure is
released), or both sides can be alternately pressurized for bi-directional
powered motion. Air cylinders are used in many positioning, actuating and
clamping applications. Choices for air cylinder style include tie rod, smooth
body, rectangular, rotating and multiple bore. Tie rod cylinders are held
together by exterior tie rods, and are usually in a rectangular bolt pattern. In a
smooth-body air cylinder, the cylinders body encases the piston. A rectangular
cylinder is encased in a rectangular, box-shaped frame. In a multiple-bore
cylinder, two or more bores and pistons combined or stacked in same air
cylinder. The cylinder can be single or double action. In a single-action device,
the cylinder contains pneumatic porting for drive in only one direction. Single-
action air cylinders frequently incorporate a return spring to the unpowered
position. In a double action device, both sides of the piston can be pressurized
for reversible motion. Force ratings can differ somewhat in opposite directions

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 VI.2. Single effect jack:_____________________
This type of jack have one way of air flow on the entrance and the exit, two of this
jacks are used in the machine to regulate the passing of the cylindrical pieces.

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VII. Motor:_________________________________
The BDSG-60-105 Series Brush DC Spur Gearmotor is a cost-effective solution for
motion control applications such as medical, semiconductor, pumps, robotics,
CNC, or whenever a low-cost Brush DC motor and a spur gearbox is required.
Available in 14 gear ratios from 3 to 150.

Features: Having curved tooth profile, these couplings have following features:

 High mechanical flexibility

 High compensation of angular, parallel and axial misalignments
 Carbon steel forged / cast hubs with hardened teeth
 Range of 19 sizes
 Power rating from 11.5 Kw to 12700 Kw at 100rpm

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 VIII. Roller:__________________________________
The roller is made of c45 steel it consists from 4 parts joined together to form the
shape of the roller. The roller is worked on a lathe machine.

 Part no 1: it is worked on a lathe machine in precision to be force fitted in the

cylinder no 3.
 Part no 2: which is the cylinder is worked with high precision to rotate with part
1 and 3.

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IX. Sensors:

IX.1. Photocell sensor__________________

Product Description
Features of IBEST M18 photo electric sensors:

-Style: cylinder, diameter: 18mm.

-Through-beam type, retro-reflective type and diffused-reflective type.

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-DC 3 wire or 4 wire; with or without M12 plug-in connector connection.
-PNP or NPN; NO or NC or NO+NC
-Light resource: Infrared LED
-Strong anti-shock and anti-vibration.

-Long detect distance: through-beam: 10m / retro-reflective type: 3M / diffused-

reflective: 5~50cm
-Fast response: through-beam: <5ms / diffusec-reflective: <3ms

-Non-contact object detect: avoid the photoelectric sensor to contact the object
directly, protect the inducing component from damage and extend the
operation life of the sensor.

-Detect any objects with different materials: detect objects by the light
quantities reflected and received, detect objects such as glass, metal, plastic,
wood, fluid...etc.

-Identify object colors: according to the colors' reflectivity and absorptive, the
sensors detect the light that the object reflected and identify the colors.
-High precision: precise electron circuit, can detect tiny objects with accurate
position.

- IP ratings: IP67
- Various other shapes: M12/M30 and square types

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IX.2. Capacitive sensor________________

Capacitive Sensor:
This sensors are particularly used for sensing non-metal such as glass, plastic,
wood, paper ,liquid, water, powder etc

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 V. MACHINE DE
TRIAGE

I. Présentation du projet

II.1. Caractéristiques du programme :

Cette machine a trois mouvements essentiels. Ces trois mouvements peuvent
être roulé en deux sens de translation autre sens à l’intention de fournir un
autre chemin pour opérer le machine en modifiant son programme. Ces
mouvements sont :
 Mouvement verticale (Axe Z).
 Mouvement longitudinal (Axe X).
 Mouvement transversal (Axe Y).

II.2. Encombrement et Condition du

projet :
Les conditions du notre projet :
 L’énergie disponible : une tension continue 12 et 24 volts et de l’aire
comprimer.
 Hauteur (1250mm).
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 Longueur (790mm).
 Largeur (590mm).
 Le charge est de 0.2 a 1 Kg.
 La vitesse maximale est de 0.1 a 1m\s pour le mouvement de translation
et pour les mouvements de la rotation 30 a 60 degrés \sec.
 La pression que nous pouvons obtenir est approximativement 1 mm.
 Il est programme par un automate programmable
 L’operateur utilise des fils flexibles.
 La matière utilisée principalement est l’aluminium.

II. Partie mécanique

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III.1. Choix technologiques :
Dans cette section, nous en discuterons quelqu’un de méthodes
mécaniques qui pourraient être utilisées dans notre projet. Tel que :
Pour les éléments en mouvement : nous avons utilisé le système de courroie de
synchronisation avec un moteur et l’action pneumatique
Mais il Ya beaucoup d’autre solutions utiles comme :
A-roue et chaine :
Il a utilisé pour déplacer des charges lourdes mais il a besoin d’entretien
périodique, en lubrifiant le système aussi, c’est bruyant de cher.

B-crémaillère et roue :
Ce type est utilisé pour les usages exacts. C’est critique, cher mais il peut être
utilise dans notre système. Bien que, il sera fabrique difficilement.

C-vis et noix :
Cette méthode peut soulever des charges extrêmes mais nous avons besoin d’un
moteur de haute vélocité et c’est cher, aussi il a besoin d’un système lubrifiant.

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III. Description du système

IV.1. Mouvement longitudinal :_______

Le mouvement est assure grâce à un système poulie courroie entrainé par un

moteur CC le guidage est assure par quatre douille à bille et de axe de
translation

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IV.2 Mouvemen axial transversal :____
Le mouvement est assure grâce à un système poulie courroie entrainé par un
moteur CC le guidage est assure par quatre douille à bille et de axe de
translation

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IV.3. mouvement vertical :_________________

Cette mouvement est assure grâce a un vérin a deux tige

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 IV. Butée
V.1. Caractéristiques générales :__________
La butée à simple effet ne supporte que des charges axiales dans un seul sens.

V.2. Emplois :___________________________

Elle convient particulièrement pour des arbres verticaux frottement charges
axialement et tournent lentement.

V.3. Désignations :_________________________

Cette butée supporte seulement une charge axial est égale à 250N, telque le
diamètre de l’arbre est égale a 26mm qui tourne à 60 tr/min .sachant que la
fréquence de rotation de l’arbre n=60tr/min .donc la charge dynamique c
=9800N (d’après la série 02SKF).
Désignation de la butée est 26TA 12
26 : le diamètre de l’arbre
TA : symbole de la butée ISO

V. Roulement
VI.1. Introduction :_____________________

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 The load is distributed on four wheels of which it is equal to 300
N. So on each wheel the load is equal to 75N.This load is called
"radial load".

There is a small axial force caused by the axis which fixes the
wheel with the bearing, it is equal to approximately 10 N.

The diameter of the shaft is equal to 20 mm, knowing that the rotation frequency
of the shaft n = 60 rpm

VI. Accouplement

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 VII.1. Généralité___________________
In order to make a connection between two rotating shafts in the mechanical power
transmissions thus transmitting the rotational movement in use of the couplings.

In mechanical engineering there are two types of coupling:

 Rigid coupling.
 Elastic coupling (semi-elastic).

The second type of coupling was used in our machine.

Elastic Coupling:
This type is used to transmit the rotational motion of two shafts with the defect indicates for
the composite to damp the vibration and shocks through the elastic elements used to exit the
system (receiver)
And sometimes to get in and out at the same time.
caoutchouc

VII. Courroie

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VIII.1. Role :_____________________________
There are two belts, one for transverse displacement and another for horizontal
displacement with respect to the transverse belt, is intermediate between a
driving pulley connected to the motor and a driven pulley placed opposite from
the driving pulley. As the second belt is intermediate between a driven pulley
and a driven pulley, their role is initiated to translate the carriage horizontally.

VIII.2. Effort appliques :________________

The applied efforts are:
 peripheral effort.
 initial voltage.

PARTIE RDM
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(2D)
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(2D)
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(2D)
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(2D)
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PART VI :
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CONTROL PART COMMAND

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GRAFCETS

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LISTING INPUTS

PROGRAMATION
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