Assignment Industrial Control

Muhammad Norul Nazmi Bin Md.Nor#1, Nur Hadi Bin Norazman*2, Mohammad Asyran Bin Dunya#3, Mohd Firdaus Bin Mohd Dahari#4 Two recommendations for station storage in FMS-200 AbstractFMS-200 system is the ideal answer to integral training in industrial automation. It is fully modular and flexible equipment and in keeping with industrial reality. This assignment to search a problem and solved the problem at FMS-200 and we search at FMS-208 that meaning station 8 is the part of storage. Key words FMS-208 station 8 part of storage, two problems, solved this two problem. I. INTRODUCTION The FMS-200 system is the ideal answer to integral training in industrial automation. It shows a flexible equipment and in keeping with industrial reality. This technologies has a different assembly stations and the assembly process with several variants, allow to user to develop the professional skills required by todays automated industry. Who has a successful experience with FMS-200, guarantees that it is training equipment of exceptional reliability used and quality by companies and teaching centers throughout the world. The transport system has two alternative forms of transferring the final product to different stations, first form using a 4 metre long bidirectional conveyer belt which allows attaching of up to 8 workstations and secondly forms using modular conveyer belts. All workstation has a structure based on aluminum profiles to carry out the corresponding process was located and all workstation has the different process by using different technologies used in automated industry such as body supply, bearing supply, hydraulic press, shaft supply, cover supply, screws supply, robotized screwing and storage. FMS-201 is the workstation name for body supply, this station acts as the support to the product assembled is fed, and moved to the pallet located in the transfer system. FMS-202 name for workstation bearing supply, this station has a four part such as feeding the bearing, transfer to the measuring module, measuring the height and insertion of the bearing. FMS-203 is the hydraulic press workstation, this phase the process carries out the hydraulic pressing of the bearing inserted in the previous station and the lower part of the station contains all of the hydraulic equipment which is required to feed the pressing cylinder with high pressure oil. Fourth station is shaft supply and is name FMS-204, the shaft is assembled on the product in process coming from the previous station. There are two types of shafts depending on the material of which they are manufactured: aluminum and nylon. For FMS-205, for cover supply to inserts a lid on the set of parts which have been assembled from the previous stations, six different types of lids depending on the material(aluminum or nylon), color(light or dark)and height(high or low). For sixth station to supply a screws and its name FMS-206, this station in charge of inserting four screws in the base of the work in process, given that the feeding is carried out at only one point, an additional mechanism has been included in the transfer to carry out the successive rotations in the pallets. For the seventh FMS-207 is robotized screwing station to integrate robotics as technology which is widely used in automated environments. A robot is used to screw in the four bolts supplied by the previous station. The robot has a tool attached with a pneumatic gripper and an electric screwdriver and the station table includes two warehouses for material (with capacity for 6 lids and 6 shafts in different materials, colors and heights). Lastly, FMS-208 is the storage stations to assembly process consists in the storage of the finish products, in this station the warehouse has been set up using a system based on two coordinates shafts and third vertical shaft for the collection of the material and we have search what problem it has, and solved it with additions components to this storage. To get the best performance from the system, we should follow this recommendation such as the floor should be level and dont have a ridging, in the vicinity there must be no heavy machinery producing noise or vibration, the working environment must be dust free, with no splashing of liquids, humidity normal with no condensation, keep EMI(Electromagnetic Incompatibility) sources at a distance as far as is possibility, check out the quality of the earth connection and lastly, atmosphere temperature must be moderate and extremes of temperature avoided.

Figure1: Complete workstation for FMS-200

II. PROBLEM STATEMENT From our knowledge, the storage can be improve and modify every component that related to the storage. In my opinion, storage is the last part of the system where the product store. So, it must be huge and high volume of space in the storage. In normal operation, the vertical axis which pick up the product and then move to the positioned at the storage point. If the products not big or only a few, its can not cause a problem, but when the big and many product to replace, it may cause big problem. In our opinion, to save space in the storage, the vertical axis must pick up the product and arrange the product following to its volume. So that, the system can store a big amount of products. III. WORLD OF SENSOR A sensor (also called detector) is a converter that measures a physical quantity and converts it into a signal which can be read by an observer or by an (today mostly electronic) instrument. For example,a mercury-in-glass thermometer converts the measured temperature into expansion and contraction of a liquid which can be read on a calibrated glass tube. A thermocouple converts temperature to an output voltage which can be read by a voltmeter. For accuracy, most sensors are calibrated against knownstandards. Sensors are used in everyday objects such as touch-sensitive elevator buttons (tactile sensor) and lamps which dim or brighten by touching the base. There are also innumerable applications for sensors of which most people are never aware. Applications include cars, machines, aerospace, medicine, manufacturing and robotics. A sensor is a device which receives and responds to a signal when touched. A sensor's sensitivity indicates how much the sensor's output changes when the measured quantity changes. For instance, if the mercury in a thermometer moves 1 cm when the temperature changes by 1 C, the sensitivity is 1 cm/C (it is basically the slope Dy/Dx assuming a linear characteristic). Sensors that measure very small changes must have very high sensitivities. Sensors also have an impact on what they measure; for instance, a room temperature thermometer inserted into a hot cup of liquid cools the liquid while the liquid heats the thermometer. Sensors need to be designed to have a small effect on what is measured; making the sensor smaller often improves this and may introduce other advantages. Technological progress allows more and more sensors to be manufactured on a microscopic scale as microsensors using MEMS technology. In most cases, a microsensor reaches a significantly higher speed and sensitivity compared with macroscopic approaches. IV.SENSOR DEVIATIONS If the sensor is not ideal, several types of deviations can be observed: The sensitivity may in practice differ from the value specified. This is called a sensitivity error, but the sensor is still linear. Since the range of the output signal is always limited, the output signal will eventually reach a minimum or

maximum when the measured property exceeds the limits. The full scale range defines the maximum and minimum values of the measured property. If the output signal is not zero when the measured property is zero, the sensor has an offset or bias. This is defined as the output of the sensor at zero input. If the sensitivity is not constant over the range of the sensor, this is called non linearity. Usually this is defined by the amount the output differs from ideal behavior over the full range of the sensor, often noted as a percentage of the full range. If the deviation is caused by a rapid change of the measured property over time, there is a dynamic error. Often, this behavior is described with a bode plot showing sensitivity error and phase shift as function of the frequency of a periodic input signal. If the output signal slowly changes independent of the measured property, this is defined as drift (telecommunication). Long term drift usually indicates a slow degradation of sensor properties over a long period of time. Noise is a random deviation of the signal that varies in time. Hysteresis is an error caused by when the measured property reverses direction, but there is some finite lag in time for the sensor to respond, creating a different offset error in one direction than in the other. If the sensor has a digital output, the output is essentially an approximation of the measured property. The approximation error is also called digitization error. If the signal is monitored digitally, limitation of the sampling frequency also can cause a dynamic error, or if the variable or added noise changes periodically at a frequency near a multiple of the sampling rate may induce aliasing errors. The sensor may to some extent be sensitive to properties other than the property being measured. For example, most sensors are influenced by the temperature of their environment.

All these deviations can be classified as systematic errors or random errors. Systematic errors can sometimes be compensated for by means of some kind of calibration strategy. Noise is a random error that can be reduced by signal processing, such as filtering, usually at the expense of the dynamic behavior of the sensor.

V. ULTRASONIC SENSOR We encourage this system using sensor or detection sensor to sense the right place to put the certain volume of product. There are many type of sensor use fo this operation. Ultrasonic sensor work like radar or sonar which is transmitting the echo or sound wave respectively and received back by the sensor, the sensorcalculate the time interval between sending the signal and receiving the echo to determine the distance to an object. Ultrasonic sensor alsohave long been used for range measurements, tank level control, web brake and proximity detection when difficult environments include challenging reflection surfaces. This type of sensor very suitable work in a box or storage that have minimun space. Ultrasonic sensor also have extreme accuracy which is, it can detect the different volume of every product to pick up and place. There are few type of ultrasonic sensors in the market according to function what ever condition. Below is the list of ultrasonic sensor :A) Self contained sensor

C) Set Point Controllers

These are control devices that have adjustable set points, and this type also can adjust its set point controllers with your choice of one or four set points. Under this type of sensor includeM-1000 which is for An analog controller with four individual set-points and temperature compensation and SPC-701 which is its Set point controller for One adjustable set point. D) Ping Sensor

Devices where the sensor and the controller are built into the same unit. Ranges 2 inches to 40 feet. There are few types under this family sensors such as RPS-150(Ranges: 2-40", 5-80"),RPS401,426(Ranges: 4-40", 8-80") B) Intrinsically Safe and Explosion-Proof Sensors non-contac distance measurement within 2cm to 3 m range. Simple pulse in and out communication. Burst indicator LED shows measurement in progress. 20 mA power consumtion and 5 vdc. Narrow acceptance angle.

Ultrasonic sensors for use in environments classified as hazardous. Ranges 4 inches to 18 feet. There are few types under this family sensors such as RPS-326-X

RESULT From the many type of sensor we explain above, the suitable ultrasonic sensor to aply in this system is ping ultrasonic sensor because it provides a very low cost and easy method of distance measurement. This sensor is perfect for any number of applications that required by this system to perform measurements between moving or stationary objects. Furthermore,this type of sensor is familiar to student and easy coding to create. The LED can show us the progression of measurement activity status. The circuit also simple because it ruquires only one i/o pin.The Ping sensor measures distance using sonar, the pulse is transmitted from the unit and distance to target is determined by measuring the time required for the echo return, Output from the ping

sensor is a variable width pulse that corresponds to the distance to the target.This sensor only requires 20 mA power consumtion and 5 vdc, which is any microcontroler can use it include pic 16f84.We can patch the sensor on the vertical axis and when the vertical axis parking the product, it can sense the suitable area to park the product. VI. SUCTION CUP

To calculate the force of a suction cup, use the formula

where F = force, A = area, P = pressure. This is derived from the definition of pressure, which is

The pressure on a suction cup as exerted by collisions of gas molecules holds the suction cup in contact with the surface.

The working face of the suction cup has a curved surface. When the center of the suction cup is pressed against a flat, non-porous surface, the volume of the space between the suction cup and the flat surface is reduced, which causes the fluid between the cup and the surface to be expelled past the rim of the circular cup. When the user ceases to apply physical pressure to the centre of the outside of the cup, the elastic substance of which the cup is made tends to resume its original, curved shape. Because most of the fluid has already been forced out of the inside of the cup, the cavity which tends to develop between the cup and the flat surface has little to no air or water in it, and therefore lacks pressure. The pressure difference between the atmosphere on the outside of the cup, and the low-pressure cavity on the inside of the cup, is what keeps the cup adhered to the surface. The length of time for which the suction effect can be maintained depends mainly on how long it takes for fluid to leak back into the cavity between the cup and the surface, equalizing the pressure with the surrounding atmosphere. This depends on the porosity and flatness of the surface and the rim of the cup. Artificial suction cups are believed to have first been used in the 3rd century, B.C., and were made out of gourds. They were used to suction "bad blood" from internal organs to the surface. Hippocrates is believed to have invented this procedure. The first modern suction cup patents were issued by the United States Patent and Trademark Office during the 1860s. TC Roche was awarded U.S. Patent No. 52,748 in 1866 for a "Photographic Developer Dipping Stick"; the patent discloses a primitive suction cup means for handling photographic plates during developing procedures. In 1868 Orwell Needham patented a more refined suction cup design, U.S. Patent No. 82,629, calling his invention an "Atmospheric Knob" purposed for general use as a handle and drawer opening means.[2][3]

For example, a suction cup of radius 2.0 cm has an area of (0.020 m)2 = 0.0013 square meters. Using the force formula (F = AP), the result is F = (0.0013 m2)(100,000 Pa) = about 130 newtons, assuming the pressure inside the suction cup is negligible when compared to atmospheric pressure (about 101,000 Pa). A) USES

Suction Cup devices often ship with suction cup holders for mounting on windscreens. Suction cups have a number of commercial and industrial applications. In office and household settings, they are commonly used to affix objects (ranging from signs to mugs) to nonporous vertical surfaces such as refrigerator doors and tiled walls. Large suction cups are used to temporarily hold and move large panes of glass and are often utilized when fitting automobile windscreens, raised floor tiles, etc. Suction cups are also found on Nerf darts and toilet plungers.[4] Specialized suction cups have also been utilized by urban climbers to scale buildings with smooth exterior surfaces.[5]

B) COMPARISON BETWEEN BELLOW CUP AND FLAT CUP

A safety factor of at least 2 for horizontal lifts should always be used to compensate for numerous variables surrounding lifting applications while a safety factor of at least 4 should be used for vertical or tilting applications. A pull-off test should be performed at our factory to determine the absolute suction cup for your particular application. VI.CUP SELECTION The Best Solution for Material Handling. Vacuum suction cups can hold, lift or turn virtually any kind of material in the production process. The contact between a suction cup and the object to be handled is soft and light, and the technique is simple and safe. Choosing the Right Suction Cup. It is very important to choose the most appropriate type of vacuum suction cup, to obtain optimal results. ANVER has cups suitable for round, inclined, curved and irregular surfaces, and with our range of products you can find the best solution for every task. VII.DISCUSSION Based on the sources and the results that have been obtained, we realize that analyzing for suitable component is needed for upgrading a system. In order to choose the best system to be upgraded, the characteristic of the system must be considered such as performance, flexibility, installation and maintenance including cost. As we learn the theory in the class, we can adaptation the knowledge by applied it into the system such as for designing hydraulic and pneumatic cylinder in the system. By applying the knowledge, we more understand the system flow. One of knowledge is the function of the air treatment unit located at the pneumatic supply input is consist of a pressure regulator to control the pressure of air to pneumatic features and is to ensure that the air is to be used at the station is in the appropriate condition. As we learn the theory in the class, we can adaptation the knowledge by applied it into the system such as for designing hydraulic and pneumatic cylinder in the system. By applying the knowledge, we more understand the system flow. One of knowledge is the function of the air treatment unit located at the pneumatic supply input is consist of a pressure regulator to control the pressure of air to pneumatic features and is to ensure that the air is to be used at the station is in the appropriate condition. Adding section cup that we use in this system is very effective way to pick up the heavy load. Normally in storage it have four flat section cup and every flat section cup can pick up 1.13KG and total four flat section cup can pick up the total heavy 4.52KG. So if adding one section cup it can improve the strength of the storage robot.

The selection of a suction cup depends on particular conditions such as surface quality and structural stability of the work piece to be lifted and the desired material, shape, etc. of the suction cup. However, a simplified formula can be used to generate a theoretical estimate based on a few known values. The diameter of the suction cup can be determined using the following formula:

VIII. CONCLUSION As a conclusion, this FMS-200 is a solution for the industrial automation training where all element or aspect in related with industrial automation can be study and analyze from it. The technology that being used in industrial automation can be studied in the practical approach by gaining the functions and applications of the different components applied in it. The overview of the real automation industry can be obtained thus improved the knowledge and skills on the technologies used in industry. Adding flat section cup is the best method to solve problem pick up the heavy. ACKNOWLEDGMENT In brief, the FMS-200 system is the ideal answer to integral training in industrial automation. It is fully modular and flexible equipment and in keeping with industrial reality. The

technologies included in its different assembly stations, as well as the assembly process with several variants, allow the user to develop the professional skills required by today's automated industry.The successful experience of the FMS-200 guarantees that it is training equipment of exceptional quality and reliability used by companies and teaching centers throughout the world. REFERENCES
[1] "Suction Cup" m-w.com". Merriam Webster: An Encyclopedia Britannica Company. Retrieved 2012-06-01. [2] "United States Patent 52,748". [3] "United States Patent 82,629". [4] "Internet Archive Wayback Machine". Web.archive.org. 200604-24. Retrieved 2012-01-27. [5] "BBC News - Man climbs skyscraper with suction cups". Bbc.co.uk. 2010-09-07. Retrieved 2012-01-27.