Design and implementation of automatic storange and classification systems

7 2.5.4 Model of a circular automatic goods storage warehouse .... 7 Figure 2.5: Model of circular automation of goods storage .... Therefore, to meet the needs of import and export at a

FACULTY FOR HIGH QUALITY TRAINING

GRADUATION THESIS ELECTRONICS AND TELECOMMUNICATION

ENGINEERING TECHNOLOGY

Ho Chi Minh City, August, 2023

LECTURER: Ph.D PHAN CONG BINH STUDENT: LE QUANG HUY

TRAN CAO NGUYEN

LE THANH TUAN

SKL 0 1 1 0 7 9

DESIGN AND IMPLEMENTATION OF AUTOMATIC STORAGE AND CLASSIFICATION SYSTEMS

FACULTY OF MECHANICAL ENGINEERING

MECHATRONICS

GRADUATION THESIS

Instructor: DR PHAN CÔNG BÌNH

Ho Chi Minh City, July 2023

Topic: “DESIGN AND IMPLEMENTATION OF AUTOMATIC

STORAGE AND CLASSIFICATION SYSTEMS”

1 Lê Quang Huy MSSV: 19146124 Phone number: 0774143136

2 Trần Cao Nguyên MSSV: 19146002 Phone number: 0896395830

3 Lê Thanh Tuấn MSSV: 19146029 Phone number: 0949554302

1 Topic code: 22223DT336

Topic: “Thiết kế và thi công hệ thống phân loại và lưu kho tự động”

2 Early figures and documents:

- The design model's frame size is 1200x1500x1000 (mm)

- Estimated import and export capacity of 100 products/hour

- Pallet size 150x75x85(mm), maximum weight 5kg

3 Main content:

- The system's mechanical component consists of a framework, a conveyor, motors, and chains

- The Control interface has two operating modes: Manual and Auto

- Design automatic storage and classification system controlled by PLC and monitored through Microsoft Visual Studio and WinCC interface

- Product information and stock status are stored in the database

KHOA CƠ KHÍ CHẾ TẠO MÁY

Bộ môn CƠ ĐIỆN TỬ

CỘNG HÒA XÃ HỘI CHỦ NGHĨA VIỆT NAM

Độc lập - Tự do - Hạnh phúc

o0o

II

6 Language: Written in English □ Vietnamese □

Presented in: English □ Vietnamese □

HEAD OF FACULTY

(Signature and full name)

HEAD OF DEPARTMENT

(Signature and full name)

INSTRUCTOR

(Signature and full name)

□ Allowed to defend a thesis

(Instructor, signature and full name)

III

COMMITMENT

Project: “Design and implementation of automatic storage and classification system”

Instructor: Dr Phan Công Bình

Student 1: Lê Quang Huy MSSV: 19146124 Class: 19146CLA1

Address: 182 Nguyễn Thị Định, P An Phú, TP Thủ Đức

Phone number: 0774143136 Email: 19146124@student.hcmute.edu.vn

Student 2: Trần Cao Nguyên MSSV: 19146002 Class: 19146CLA1

Address: Tổ 6, Khu phố 5, Uyên Hưng, Tân Uyên, Bình Dương

Phone number: 0896395830 Email: 19146002@student.hcmute.edu.vn

Student 3: Lê Thanh Tuấn MSSV:19146029 Class:19146CLA1

Address: Kp Định Thắng 1, Thị Trấn Phú Hoà, Phú Hoà, Phú Yên

Phone number: 0949554302 Email: 19146029@student.hcmute.edu.vn

Graduation thesis submission date: 21/07/2023

Commitment: “I hereby declare that this thesis is the work of my own research and

implementation I do not copy from any published article without citing the source I will take

full responsibility for any fraud detected in my thesis”

Ho Chi Minh City, 21st July 2023

Signature

IV

ACKNOWLEDGMENT

During the process of implementing the Graduation Thesis at Ho Chi Minh City University of Technology and Education, the team received a lot of attention and help from the teachers The team would like to express their deep gratitude to the teachers of the Faculty

of Mechanical Engineering for creating favorable conditions for the team to carry out the project

With deep gratitude, the implementation team would like to thank the instructor – Dr Phan Cong Binh has enthusiastically guided, imparted knowledge and created all favorable conditions for the group to carry out this topic

Thank you to my family and friends who have always supported and encouraged me throughout the process of studying and implementing this project

Despite their best efforts, the group will undoubtedly make mistakes despite their thorough research and implementation of the topic Consequently, the group anticipates hearing from you with comments and ideas to enhance the subject

Sincerely thanks!

Student

Lê Quang Huy Trần Cao Nguyên Lê Thanh Tuấn

V

ABSTRACT

“Design and implementation of automatic storage and classification system”

The Automatic Storage and Classification System provides an appropriate design for the warehouse and products handling The industry's objective is to convey the pallets as rapidly and inexpensively as feasible The reason for choosing this topic is because it can apply our knowledge from previous Mechatronic projects and subjects Additionally, there are few automated warehouse systems in Vietnam, the goal is to expand this system in Vietnam This system consists of Storage racks, Pallets, Movement Axes, Sensors, etc The PLC controls and coordinates the movement and performance of the system In this report, the design, operation and advantages of the new mechanism are presented Using conveyor chains to reduce investment costs and transport goods with larger loads The chain drive is used for the traveling mechanism to improve transportation efficiency as well as simple installation and easy maintenance The telescopic mechanism and the pallet shake slightly but the transmissions are still stable after three operation cycles in the automatic import and export mode This system’s implementation is simulated using SCADA The operating parameters

of the system are accomplished through the design, calculation, and control processes The productivity of the model for import and export is approximated to 3800 items per day, with the time to import and export goods for each model around 23 seconds for pallets The fundamental system satisfies the beginning requirements, including operating in the proper sequence of an actual system, having a software interface full of fundamental features, identifying, and resolving faults, and recording, storing, and exporting data as necessary It enables the cargo to be moved within a warehouse swiftly, safely and precisely

Instructor (Signature and full name)

VI

TABLE OF CONTENTS

TASKS OF GRADUATION THESIS i

COMMITMENT iii

ACKNOWLEDGMENT iv

ABSTRACT v

TABLE OF CONTENTS vi

LIST OF PICTURES AND DIAGRAMS x

LIST OF TABLES xiv

LIST OF ABBREVIATIONS xv

CHAPTER 1: OVERVIEW 1

1.1 The necessity of this subject 1

1.2 Scientific and practical significance of the topic 1

1.3 Research objectives of the topic 2

1.4 Object and range of the study 2

1.4.1 Research subjects 2

1.4.2 Research range 2

1.5 Research Methods 2

1.6 Structure of Graduation thesis 2

CHAPTER 2: RESEARCH OVERVIEW 4

2.1 Introduction 4

2.2 Working principle 4

2.3 General structure of the system 4

2.4 Methods of product classification 5

2.5 Warehouse models are being used in practice 6

2.5.1 Stacked warehouse model 6

VII

2.5.2 Automated warehouse model 6

2.5.3 Underground warehouse automation model 7

2.5.4 Model of a circular automatic goods storage warehouse 7

2.5.5 Criteria for evaluating the quality of the storage system 8

CHAPTER 3: THEORETICAL BASIS 9

3.1 Mechanical Theory 9

3.1.1 Conveyor chain 9

3.1.2 Motor selection and Ratio distribution 10

3.1.3 Sequence of calculation and design the chain drive 11

3.1.4 Transmission gear 14

3.2 Configuration of the control system 19

3.2.1 Centralized Control System I/O 19

3.2.2 Distributed Control System I/O 19

3.3 Barcode reader device 20

3.4 Programmable Logic Controller (PLC) 22

3.4.1 Introduce PLC 22

3.4.2 PLC Siemens 22

3.5 Stepper motor 23

3.5.1 Introduce stepper motor 23

3.5.2 Stepper motor control method 24

3.6 Product detection sensors 25

3.6.1 Photoelectric sensors 25

3.6.2 Proximity Sensors 25

3.6.3 Capacitance level sensors 25

3.7 Barcode theory 26

3.7.1 Introduce 1D barcode 26

3.7.2 Types of popular barcodes today [2] 27

VIII

3.7.3 Applications of barcodes in goods classification 30

3.8 SQL Database Software 30

3.9 Microsoft Visual Studio software and Windows forms App 32

CHAPTER 4: ORIENTATION AND SOLUTION 34

4.1 Request for a topic 34

4.1.1 Customer requirements 34

4.1.2 Technology Requirements 34

4.1.3 Design requirements of the model 34

4.1.4 Electrical design requirements 34

4.1.5 System configuration selection 34

4.1.6 Block diagram and function 35

4.2 Solutions to the requirements 35

4.2.1 Solutions for import-export system 35

4.2.2 Solutions on transmission mechanism 36

4.3 Selection of options 39

4.3.1 Proposing technological process 39

4.3.2 Model construction plan 40

4.3.3 Wiring Diagram 42

4.3.4 Electrical cabinet design 42

4.4 Design of control flowcharts 43

4.4.1 Control request 43

4.4.2 Drawing flowchart 43

4.5 Design the interface 44

4.5.1 Design requirements 44

4.5.2 Barcode reader interface design 45

4.5.3 Flowchart of bar code scanning program 46

CHAPTER 5: COMPUTATION AND DESIGN OF THE SYSTEM 48

IX

5.1 Power Calculation 48

5.1.1 Calculation to choose motor 49

5.1.2 Sequence of calculation and design the chain drive 50

5.1.3 Design the gear reducer 54

5.2 Design and calculate mechanisms for model 55

5.2.1 Selection of electrical equipment 55

5.2.2 Model to reality ratio calculation 63

5.2.3 Designing the Frames 63

5.2.4 Calculating the dimensions of the motion mechanism 64

5.2.5 Motion mechanism construction 66

5.2.6 Calculating the conveyor 67

5.3 Overview of mechanical design and construction 68

5.4 Construction of electrical part 68

5.5 Building the SCADA 68

5.6 Construction of barcode reading interface 70

CHAPTER 6: EXPERIMENTS-DISCUSSIONS 72

6.1 The mechanical construction for experiments 72

6.2 The electrical construction for experiments 73

6.3 The barcode reading interface for experiments 74

6.4 SCADA for experiments 74

6.5 System operation results 77

CHAPTER 7: CONCLUSIONS 83

7.1 Work done 83

7.2 Orientation of development 83

REFERENCES 84

APPENDIX I

X

LIST OF PICTURES AND DIAGRAMS

Figure 2.1: The block diagram of the system principle 5

Figure 2.2: Stacked warehouse model 6

Figure 2.3: Automated warehouse model 7

Figure 2.4: Underground warehouse automation model 7

Figure 2.5: Model of circular automation of goods storage 8

Figure 3.1: Conveyor chain 9

Figure 3.2: CCS diagram 19

Figure 3.3: DCS diagram 20

Figure 3.4: A CCD barcode scanner 21

Figure 3.5: Laser type barcode scanner 22

Figure 3.6: Stepper motor control diagram 24

Figure 3.7: Types of Barcodes 26

Figure 3.8: EAN and UPC barcodes 27

Figure 3.9: Code 39 28

Figure 3.10: Code 128 28

Figure 3.11: ITF barcode (Interleaved 2 of 5) 29

Figure 3.12: Codabar code 29

Figure 3.13: Code 93 30

Figure 3.14: MSI Plessey barcode 30

Figure 3.15: Structure of a database 31

Figure 3.16 Microsoft SQL Server Management Studio 2019 interface 32

Figure 3.17: Programming interface Windows forms App (.NET framework) 33

Figure 4.1: Block diagram and function 35

Figure 4.2: Common PVC Conveyors 36

Figure 4.3: Chain Conveyor 36

Figure 4.4: Working principle of Telescopic mechanism in real model 37

XI

Figure 4.5: Belt drive 38

Figure 4.6: Screw – nut drive 38

Figure 4.7: Chain drive 39

Figure 4.8: EAN -13 Standard Barcode 40

Figure 4.9: CONEX Dataman 8050" Barcode Scanner 41

Figure 4.10: System wiring diagram 42

Figure 4.11: Arrangement of equipment in electrical cabinets 43

Figure 4.12 Arrangement of equipment outside the electrical cabinet 43

Figure 4.13: System control flowchart 44

Figure 4.14: Database 45

Figure 4.15: Flowchart of bar code scanning program 46

Figure 5.1: Kinematic Diagram 48

Figure 5.2: MOTOR ABB - M2QA132M8A 55

Figure 5.3: PLC S7-1200 1214C DC/DC/DC 56

Figure 5.4: Wiring diagram PLC S7-1200 1214C DC/DC/DC 56

Figure 5.5: Optical sensors E3F3-D11 57

Figure 5.6: E3FE-D11 sensor wiring diagram with PLC S7-1200 57

Figure 5.7: Stepper motor 42 58

Figure 5.8: Stepper motor 75 58

Figure 5.9: Conveyor belt traction reducer motor 58

Figure 5.10: Driver TB6600 59

Figure 5.11: Driver connection diagram with stepper motor 61

Figure 5.12: Turn on the PTO high-speed pulse channel 61

Figure 5.13: Declare pulse generator pin, direction 62

Figure 5.14: Declare driver microstep and lead screw step 62

Figure 5.15: Declare speed, acceleration and deceleration time 63

Figure 5.16: The model pallet and the box of system 63

Figure 5.18: Model of Framework 64

XII

Figure 5.218: Construction of Framework 64

Figure 5.19: Telescopic mechanism 65

Figure 5.20: Construction of telescopic mechanism 65

Figure 5.21: The movement axes 66

Figure 5.22: Motion mechanism construction 66

Figure 5.23: Import conveyor 67

Figure 5.24: Import conveyor construction 67

Figure 5.25: Export conveyor 67

Figure 5.26: Export conveyor construction 67

Figure 5.307: Main screen of the system 68

Figure 5.28: Setting alarm view for system 69

Figure 5.29: Setting system permissions 69

Figure 5.30: Setting table view 69

Figure 5.31: The window of the product classification and reading interface 70

Figure 5.32: Database data 71

Figure 6.1: Hardware results 72

Figure 6.2: Inside electrical cabinet 73

Figure 6.3: Outside electrical cabinet 73

Figure 6.4 Reading and classifying products interface 74

Figure 6.5: Interface screen introduction 75

Figure 6.6: Main screen interface 75

Figure 6.7: System information screen interface 76

Figure 6.8: Alarm screen interface 76

Figure 6.9: JOG running screen interface 77

Figure 6.10: Introduction screen – Login ADMIN 78

Figure 6.11: Barcode reader interface 79

Figure 6.12: Auto mode operation screen - Import 79

Figure 6.13: The alarm screen cannot scan the barcode 80

XIII

Figure 6.14: Auto mode main screen - Export 80

Figure 6.15: Alarm screen warns that stock is out of stock 81

Figure 6.16: Info screen 81

Figure 6.17: File storage information 82

XIV

LIST OF TABLES

Table 3-1 The distribution ratio 11

Table 3-2 Chain transmission parameters 14

Table 3-3 Parameters of Gear drive 16

Table 3-4 Stepper motor angle table 23

Table 4-1 Compare the two types of chain conveyors and PVC conveyors 36

Table 4-2 Comparison of three types of transmission 38

Table 4-3 Alarm 47

Table 4-4 System authorization table 47

Table 5-1 Parameters of Motor 49

Table 5-2 Distribution ratio 50

Table 5-3 Coefficient of working condition 51

Table 5-4 Parameters of drive chain 54

Table 5-5 Specification of gear motor 55

Table 5-6 Specification of motors 58

Table 5-7 The motion of the mechanism 65

XV

LIST OF ABBREVIATIONS

PLC Programmable Logic Controller

CCS Centralized Control System

DCS Distributed Control System

I/O Input/Output

PTO Pulse Train Output

CDD Charge Coupled Device

CPU Central Processing Unit

MDF Medium Density Fiberboard

1

CHAPTER 1: OVERVIEW 1.1 The necessity of this subject

As of December 15, 2022, the import and export value of Vietnam's goods reached 700 billion USD according to the statistics of the General Department of Customs, exceeding the threshold of 668.5 billion USD according to the Ministry of Industry and Trade Trade in

2021 In which, the total import and export turnover in the last 10 years from 2012 to 2021 has reached 4110 billion USD, nearly 4 times higher than the import and export value of goods 10 years ago the combination.[5]

Facing the strong development momentum of the domestic economy and the integration trend of the world economy, industries must always meet the stages of production and import and export operations quickly and accurately Along with the growth of industries and the economy, the number of output products and input goods increased sharply Therefore, to meet the needs of import and export at an increasing rate today, the classification, import and export of goods and automatic storage is a great achievement in the process of economic development home country in particular and the global supply system in general

In Vietnam, this automatic technology is still being applied and improved every day to meet the needs of import and export, storage and transportation of goods The most effective method is a smart warehouse, which helps to reduce human labor, optimize the operation of sorting and importing and exporting warehouses accurately and quickly In addition, smart warehouse helps to optimize storage space and manage goods in the warehouse in real time

in the most effective and scientific way through barcode classification of goods The above benefits are the reason that motivates my group to research the topic: "DESIGN AND

IMPLEMENTATION OF AUTOMATIC STORAGE AND CLASSIFICATION SYSTEM"

1.2 Scientific and practical significance of the topic

Applying an automatic sorting and storage system is an important factor that plays an important role in increasing productivity, saving costs and labor The positive sides when companies use automation systems in practice include:

- Increase labor productivity: automatic sorting and storage lines can operate continuously 24/24 with much higher productivity than manual control without human intervention Therefore, the volume of goods entering and leaving the warehouse will be more than not applying automation to the warehouse

- Easy to monitor, avoid errors when classifying and entering and leaving warehouses: the automation applications are programmed correctly, there will be a significant reduction in errors in the process of sorting and importing and exporting warehouses

2

compared to other operations conventional craft

In addition, automation also helps to increase the competitiveness of enterprises, increase flexibility, cut labor costs and many other costs

1.3 Research objectives of the topic

- Reduce labor and save operating costs for businesses

- Increase the efficiency of warehouse management

- Automate the intelligent warehouse control system by PLC and monitor the system

in real time

- Save space for goods storage

- Reduce occupational accidents

1.4 Object and range of the study

1.6 Structure of Graduation thesis

The rest of the thesis has the following content:

Chapter 2: Overview of the topic research

3

The main content of chapter 2 is to introduce classification methods, automatic storage system, configuration of centralized input and output system, distributed input and output; introduce types of PLCs, sensors, etc available on the market; Barcode theory

Chapter 3: Theoretical Basis

The main content of chapter 3 is to determine the sequence of calculation drive system and choosing the available motor, ratio; introduce classification methods, automatic storage system, configuration of centralized input and output system, distributed input and output; introduce types of PLCs, sensors, etc; Barcode theory

Chapter 4: Orientation and solutions of storage system

Present the requirements of the topic such as design, calculation, technology requirements Provide solutions to model manufacturing and propose technology for models Besides sketching the console for the user-friendly system

Chapter 5: Calculation and system construction

Calculating and choosing the motor which has power and transmission ratio available for the system Presenting the detailed construction steps of mechanical operation of the system, construction of electrical cabinets and completion of the automatic storage and classification system Manipulating configuration settings and programming for the system Chapter 6: Experiment and discussion

Presenting the results that the team has implemented, including the results of mechanical construction, electrical control, barcode reading interface, system control and monitoring interface, and actual operating results of the system Based on practical results to make a comprehensive review and evaluation for the automatic classification and storage system Chapter 7: Conclusion

Summarize the work that the team has done successfully and the outstanding problems

of the system model and suggest future development directions for the topic

4

CHAPTER 2: RESEARCH OVERVIEW

Automated engineering technology has been applied to the automatic sorting and storage system Carrying out the application of part or all of production activities from human labor to machinery and equipment The special feature of the automation process is that it does not need too much human intervention to operate the machines The system can operate itself automatically and smoothly thanks to the control systems

2.1 Introduction

Currently, some large companies in the world have applied the form of automatic warehouse As a result, Amazon's warehouse productivity has increased by 40% of revenue and operating costs are reduced to less than 10% thanks to the application of the CFN (Customer Fulfillment Networking) strategic model This technology has greatly helped the company's business from its use to the smart storage system

This is an example of the great benefits that automatic storage systems have brought

to businesses Therefore, our team proposed the idea for an automatic storage and sorting system model controlled by PLC S7-1200 The model is designed by the group according to some practical requirements to optimize the operation of the system

2.2 Working principle

The automatic sorting and storage system is designed to include: A loading structure for loading and unloading goods from the warehouse, a mechanism that moves vertically between two warehouse compartments, a push-and-draw structure In general, the automatic warehouse is composed of 3 parts:

- Loading and unloading system

- Freight system

- Warehouse

2.3 General structure of the system

Monitoring the distribution of goods to avoid errors in the operation of the warehouse is very important In the process of monitoring and control, the control of incoming and outgoing goods needs to operate continuously with high accuracy to increase productivity and avoid unnecessary errors

To meet the above requirements, the system needs to be designed to ensure the following functional blocks in Figure 2.1:

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Figure 2.1: The block diagram of the system principle Based on the requirements of the topic, the team determines the appliances, electrical - electronic components, design components or determine the product design steps as follows:

- Supply block: Determined according to the current power source on the market, providing operating power for electrical equipment in the system

- Display block: Receiving and processing images, communicating to the controller

- Sensors: Collect signals and send them to the controller to control the operating mechanisms

- Controller: Receives signals from sensors and barcode scanners to control actuators

- Operating mechanism: The motor fulfills the request of the controller

2.4 Methods of product classification

In accordance with the requirements of the system, it is possible to choose the methods

of classifying products circulating on the market today, including the following methods:

- Method of product classification by weight

- Method of product classification by color

- The method of product classification by height

- Method of product classification by barcode

6

2.5 Warehouse models are being used in practice

2.5.1 Stacked warehouse model

The stacked warehouse model in the Figure 2.2 [11] applies a hydraulic system to lift

up to 4 boxes of onions side by side to a high floor to make room for another 4 boxes below

Figure 2.2: Stacked warehouse model However, this is not the optimal solution economically, so it is only suitable for small-scale systems

2.5.2 Automated warehouse model

The warehouse automation model is an improvement over the stacked model above in terms of increased capacity many times over By arranging goods close to each other and reducing the distance between floors, the stages of importing, storing or exporting goods are completely controlled automatically with the help of modern technology

As a result, the control and monitoring of warehouse operations becomes easy

The structure of an automatic warehouse system consists of 2 parts:

- Warehouse to store goods

- Forklifts

Forklifts are connected to programming equipment and other control devices to operate and deliver goods to locations in the warehouse The system is shown in Figure 2.3 [13]

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Figure 2.3: Automated warehouse model

2.5.3 Underground warehouse automation model

The underground automatic cargo storage model in Figure 2.4[13] has the same operating structure as the automated goods storage but has an underground design

Figure 2.4: Underground warehouse automation model This model can save storage space, but the implementation problem Installation and

maintenance costs are high, leading to some difficulties that may be encountered

2.5.4 Model of a circular automatic goods storage warehouse

The Model of circular automation of goods storage is improved with a greater degree of prudence than the previous models Rows are arranged in several layers, and these row cells are arranged in a circle This model is shown in Figure 2.5 [13]:

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Figure 2.5: Model of circular automation of goods storage Advantages:

- The quantity of goods that can be stored is relatively large

- Application in warehouses with a large number of goods with a relatively high density of goods

- High degree of automation

- Easy to control and monitor

Disadvantages:

- High cost

2.5.5 Criteria for evaluating the quality of the storage system

- The number of goods the system can handle

- Degree of automation

- Optimizing the control and monitoring operation process

- Cost of installation, maintenance and labor to operate the system

- The ability to store large quantities and retrieve data easily

- Ensure safety in operation

- Minimize errors in the working process of the system

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CHAPTER 3: THEORETICAL BASIS

Simplifying the process of sorting and checking inventory to avoid errors in the operation and management of the system plays a key role in evaluating the application of an automated warehouse system in practice Thus, for effective management and operation, individuals and businesses need to master the steps in the process of managing and monitoring automatic classification and storage systems

3.1 Mechanical Theory

3.1.1 Conveyor chain

Chain conveyors are used primarily in the mining, manufacturing technology materials manufacturing or industrial warehouse In this report, chain plate conveyors are considered and placed horizontally Figure 3.1 is an example of a chain conveyor

Figure 3.1: Conveyor chain Calculation of conveyor chain system with specific parameters: pitch p(mm), number of teeth on driving sprocket Z, width of conveyor chain B(mm), length of conveyor chain L(mm), velocity of conveyor chain v(m/s), loads G(kg), productivity of number product Qsp

(product/hour), weight of 1m chain q(kg/m), coefficient of uneven feed k

The power on driving sprockets shaft (working shaft) is calculated by the formula:

𝑃𝑙𝑣 = 0,0024 × 𝑞 × 𝑣 × 𝐿 + 0,00033 × 𝑄 × 𝐿 + 0,006 × 𝑄 × 𝐵 (𝑘𝑊) (3.1) Q(ton/hour): The productivity of conveyor chain’s weight: 𝑄 =𝐺×𝑘×𝑄𝑠𝑝

1000 (3.2) Rotation speed of working shaft:

𝑛𝑙𝑣 =60000×𝑣

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3.1.2 Motor selection and Ratio distribution

Preliminary ratio is calculated by the formula:

Calculating the rotation speed on shafts

- Rotating speed of shaft 1:

Calculating the torque on shafts:

- Torque on motor’s shaft:

Then we have the Table 3-1 represents the distribution ratio:

Table 3-1 The distribution ratio Shaft

3.1.3 Sequence of calculation and design the chain drive

Choosing chain: Roller chains

Power on chain drive shaft: 𝑃1 = 𝑃2

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Rotation speed of drive shaft: 𝑛1 = 𝑛2

Transmission ratio of chain drive 𝑢 = 𝑢𝑥

Working condition of chain drive, it can assume condition like: shifts of working, working environment, impact load [8]

According to the table 5.4 [8], choosing the number of teeth on small disk

The number of teeth on large disk: 𝑍2 = 𝑢 × 𝑍1 (3.23) Real transmission ratio:

Then comparing with the allowable power 𝑃𝑡 ≤ [𝑃𝑜] and determine the pitch of chain p Determine center distance and chain link:

Initial center distance:

13

Durability test: 𝑆 = 𝑄

According to the table 5.2 [8], we can determine the destructive load Q and the Weight

of 1m chain q, 𝑘đ ( coefficient of dynamic load)

𝐹𝑡 = 1000 ×𝑃

With 𝑣 = 𝑝×𝑍1×𝑛

Investigate the chain for contact strength:

𝜎𝒉 = 0,47 × √𝑘𝑟× (𝐹𝑡 × 𝑘đ + 𝐹𝑣đ) × 𝐸

𝑘𝑟 = 𝑘1+ (𝑍1− 𝑍𝑎) ×𝑘2 −𝑘1

Impact force on a chain Fvđ: 𝐹𝑣đ = 13 × 10−7× 𝑛1× 𝑝3× 𝑚 (3.41)

With an inclined transmission with an angle of less than 30o, kx = 1,15

Determine pitch circle diameter d1, d2:

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Finally, we summarize by the table of chain transmission parameters in the Table 3-2

Table 3-2 Chain transmission parameters

Pitch circle diameter of driving disk d1 (mm)

Pitch circle diameter of driven disk

d2 (mm)

f2 (mm) Number of chains

3.1.4 Transmission gear

Power on gear drive shaft: 𝑃1 = 𝑃1

Rotation speed of gear shaft: 𝑛1 = 𝑛1

Transmission ratio of gear drive 𝑢 = 𝑢𝑏𝑟

Moment on gear shaft: 𝑇1 = 𝑇1

The working time based on early documents

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Determine the available stress: Choosing the hardness HB1, HB2 Calculating the contact stress [H1], [H2] and then bending stress [F1] , [F2] After that choose [H] so that it is smaller the value than [H1], [H2] Finally, we determine the available stress when it’s overloaded: section 6.2[8]

ZM, ZH we can check into the table 6.5, 6.12 [8]

Z - coefficient the coincidence of teeth

𝑍𝜀 = √(4−𝜀𝛼)

Summary the parameters of gear in the Table 3-3

Table 3-3 Parameters of Gear drive

Parameter Symbol Value

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Transmission ratio of gear drive u

Bevel gear is similar to opinion gear, we have the power, rotation speed, transmission, moment and working time

Sequence of calculation: choose materials and determine stress are as same as opinion gear

Determine the preliminary length of the outer taper

Choose Z1 is integer the calculate Z2 (3.23) then choose Z2 also integer

Calculate real transmission ratio and tolerance ratio

Testing the bending contact of teeth

Then testing teeth for overload like formula 3.66 and 3.67

Summary the result with the table of bevel gear parameters

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3.2 Configuration of the control system

3.2.1 Centralized Control System I/O

Centralized I/O circuits are plugged directly into the computer via expansion buses Typically used in applications where the PC is in close proximity to sensors and actuators Features: compact, fastest data collection and control speed, low cost, so often used Centralized I/O diagram is shown in Figure 3.2:

Figure 3.2: CCS diagram

3.2.2 Distributed Control System I/O

Sensors and actuators are usually far away from the PC In manufacturing, the sensor and actuator are in harsh environments and distributed over a large area hundreds of meters away from the PC

In noisy environments, it is difficult to receive small signals from sensors such as thermocouples over long transmission lines The wire from the sensor to the PC is long and can be expensive

Solution: Distributed I/O, that is the signal conditioning module is located near each corresponding sensor Each sensor needs a signal conditioning module

- RS-232 (point to point): cumbersome when there are many points

- RS-485: (multi-drop): Reduce the amount of transmission cable, can connect up to

32 modules, the transmission distance can be up to 10km if using multi-drop network (RS-232: up to 15m)

It often needs an 232 to 485 converter since most PCs do not support the

RS-485 standard

Distributed control system block diagram is shown in Figure 3.3:

Figure 3.3: DCS diagram

3.3 Barcode reader device

Currently on the market, there are many different brands of barcode readers, but in general, barcode reading devices are divided into 2 main types: CCD barcode scanners and laser barcode scanners This type of code scanner uses different technology and each has its own advantages and disadvantages

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A CCD barcode scanner is a scanner that uses an array of LEDs arranged so that the emitted light rays form a straight horizontal line of light that cuts across the surface of the barcode The reflected light obtained by the CCD scanner is used to convert the light signal into a real signal

Figure 3.4 is an example of A CCD barcode scanner:

Figure 3.4: A CCD barcode scanner Advantages and disadvantages of CCD scanners:

- CCD-type barcode scanners are characterized by their linear operation and cannot read 2D barcodes

- However, there are advantages to using linear CCD scanners because those are reliable, relatively low-cost solutions compared to laser type barcode readers for reading linear barcodes

- Bar code recognition distance is not far

- Easily disturbed by the impact of the external light environment

The laser type barcode scanner in Figure 3.5 consists of a reader eye that emits a red laser, which is then used to create a light trail that cuts across the surface of the barcode

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Figure 3.5: Laser type barcode scanner Advantages and disadvantages of laser barcode scanners:

- Laser-type barcode scanners are made up of many components, so it is more prone

to breakdowns and failures than CCD-type barcode scanners

- Better scans over 2 Feet

- Works well in low light situations

- Laser type barcode scanners are chosen primarily for hardware when you need speed and accurate barcode reading

high-3.4 Programmable Logic Controller (PLC)

PLC Siemens are suitable for communication and process control applications The initial programming will be more difficult to access, but once mastered, it will better support the user

3.5 Stepper motor

3.5.1 Introduce stepper motor

Stepper motor is actually a synchronous motor used to convert the control signal in the form of discrete electrical pulses consecutively into rotational or rotor movements and has the ability to fix the rotor at required locations

Stepper motor works because of the electronic commutator that feeds the control signals

to the stator in a certain order and frequency The total number of rotations of the rotor corresponding to the number of switches, as well as the direction of rotation and the speed of the rotor, depends on the switching order and the switching frequency

Stepper motor has many types such as rheostat, unipolar motor, bipolar motor The most common stepper motor is 1.8 degrees / 1 step (equivalent to 200 steps will get 1 revolution) There are also other motor stepping angles that can be found in Table 3-4

Table 3-4 Stepper motor angle table

Step angle Steps per revolution