A PLC-based embedded device on a miniature conveyor machine for operating a rejection system has been designed and constructed. The research objectives, namely (i) design and manufacture of an integrated system, (ii) making program structure based on a ladder diagram, and (iii) measuring the performance of an integrated system. Integrated system assembled from a miniature of the conveyor machines and belt installation, and installing the dc motor, while the rejection system assembly by placing several sensors, installing stepper motor, and wiring to the PLC system. Programming based on ladder diagram carried out by determining algorithms, compiling the ladder diagram, addressing the input/output, and compiling and uploading the program from PC to PLC. The performance of the integrated system was observed when (a) observation during synchronization, (b) observations of sensor readings while the rejection system simulator is operating, and (c) observation and measurement of the processing time of the rejection arm. Overall results have been obtained in the form of a PLC-based embedded device for the rejection system simulator on observations of the condition of the bottle caps for beverage packaging. Based on the overall observation, the PLC-based embedded device has functioned to operate the rejection system can be implemented at a manufacturing scale.
Changes to the simulator rejection system from the previous research were carried out by replacing all sensors, drive motors, PLC systems, and adding HMI systems. The objectives in this research, namely (i) changing and developing a rejection system simulator, creating a ladder-based program structure and configuring HMI systems and (ii) measuring the performance of the simulators. Rejection system simulator is fabricated and reassembled, ladder-based syntax into PLCs and HMI is also configured, and observing the performance is done through the HMI layer. The results of programming is carried out through (i) providing software for PLCs, (ii) programming the PLC system, (iii) compiling and uploading programs from PC to PLC, (iv) configuring PLC and HMI via ethernet, and (v) compiling and uploading the program structure from PC to HMI. The performance for observing the condition of the bottle cap through the HMI is observed when (i) synchronization between the simulator system and the HMI-assisted PLC control, (ii) the reading of the sensors installed on the simulator, and (iii) the rotation process of the rejector arm. Overall, the rejection system simulator with a PLC-based assisted by HMI can be used as a process simulation against the implementation of the rejection system
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