automation of belt curing process using plc · of v-belt autoclave curing . ... fig 3shows t he...
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ICNSCET19- International Conference on New Scientific Creations in
Engineering and Technology
AUTOMATION OF BELT CURING PROCESS USING PLC
Take veegrip belts Pvt. Ltd., as an example
PrithiviRaj1, Kalyanasundaram
2, Prasanabalaji
3
1EIE,KCET
2EIE,KCET
3EIE,KCET
Abstract— This paper mainly focuses on the technical improvement of curing system in the v-belt
manufacturing industry of Veegrip Pvt. Ltd. Based on the analysis of many experimental data and
under the consideration of economic benefit, a series of theoretical indicators are concluded , and it's
favourable for realizing perfect production .The main aim of this project is to automate the process
of V-belt autoclave curing . Through the automation we can reduce man power and improve the
accuracy and perfectness.PLC applications are extensively used in manufacturing industries to
control the process, so In this project we use VERSAMAX PLC for control solenoids, autoclave’s
cap and to maintain the temperature, pressure in the autoclave.
Keywords— Automation,Programmable Logic Controller,curing.
I. INTRODUCTION
Application of programmable logic control (PLC) is widely used on the control
systems in the many field engineering such as automotive, aviation, food processing and other
industries. PLC is simply program to control many automatic activity, easy to use, flexible and
others. PLC using the ladder program to solve and regulated the control system component. In
this project, PLC is used to automate the v belt autoclave curing process. Curing is the process of
applying pressure to the belt in a mould in order to give it its final shape, and applying heat energy
to stimulate the chemical reaction between the rubber and other materials. Temperatures are in the
area of 160 °C with pressures around 170psi. This heat results in chemical and physical changes in
the rubber compounds. Belts are cured for a certain duration of time depending on the type of belts.
Under-cured belts will result in lack of adhesion of components and results in failed belts. So, it is
essential to keep track of the temperature and pressure applied during the curing process and alert
the operator if there is a change in the applied temperature or pressure. Manual control of different
valves and autoclave’s cap is difficult and the process requires continuous monitoring and control of
temperature and pressure. so we are going to do automation with PLC for automate the curing
process by means of programmable thermostat, pressure switch, proximity switch, solenoids and
push pull actuator.
II. OVERVIEW OF V-BELT MANUFACTURING
The manufacturing process flow of the vulcanizer It’s manufacturing process flow shown in
Fig. 1.(take the 1800tons for example) The vulcanizing board need to be heated to 160 degree
1st International Conference on New Scientific Creations in Engineering and Technology (ICNSCET-19)
International Journal of Recent Trends in Engineering & Research (IJRTER)
Special Issue; March - 2019 [ISSN: 2455-1457]
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and maintained the degree for 20 minutes after being charged from the autoclave, then cooling
water should be poured into the vulcanizing board immediately. Usually,the time for cooling is
from 0 to15 minutes ,and then pattern drawling and discharging can begain when the temperature
is already below 60 degree.
Fig. 1 manufacturing process flow
III. LITERATURE REVIEW
PLC and the SCADA systems are widely used in most industrial processes e.g. chemical
industries, steel manufacturing, power generations, etc. Automated level control systems using PLC,
SCADA are used ubiquitously in industrial applications. To prevent industrial accidents by
overfilling of any open container, to prevent overfilling of any closed container thereby creating
overpressure condition. Therefore, process control industrial applications requires effective supervise
level control in multiple tanks.
A paper on the design of bottle filling plant using PLC wherein a bottle filling and capping operation
takes place in a synchronized manner. The user can input the desired volume of liquid to fill in the
bottles. The entire system is more flexible and time saving [3]. Another application in which
microcontroller based automated system was developed. The developed system improved the
performance by reducing the time delay using fast switching transistors. The system was tested for
electro pneumatic and electro hydraulic systems resulting in faster time response and stable duty
cycle [4].
A PLC based monitoring and control scheme for a three-phase induction motor suggested that PLC
can be used in automation industries involving control of induction motor. A control program was
developed, through which PLC continuously monitored the inputs and activated the outputs
accordingly. A current sensor was employed for load current feedback, a speed sensor for speed
feedback, and an additional current sensor was attached to stator circuits. The speed control of motor
achieved through PLC gave the system high accuracy in speed regulation at constant speed for
variable load operation. The efficiency of the induction motor system fed by an inverter was
increased appreciably by using PLC. At high speeds and loads, the efficiency of PLC-controlled
system is increased up to 10–12% [6].
IV. PROPOSAL IDEA
In v-belt autoclave curing several process work in a sequential fashion, in this stage PLCs
are used to maintain the temperature, pressure, flow and curing time. Fig 3shows the schematic block
diagram . Initially the cap of autoclave is kept open. When proximity sensor sense the metal mould
then it will check the status of pressure. If the pressure is less than 160 psi , an indication will be
given to the operator.
1st International Conference on New Scientific Creations in Engineering and Technology (ICNSCET-19)
International Journal of Recent Trends in Engineering & Research (IJRTER)
Special Issue; March - 2019 [ISSN: 2455-1457]
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Once when the operating pressure attains , the pressure will flow through valve V2 for 20 seconds as
curing time. While curing if the temperature gets higher than set point the process will be stopped
until normal temperature attains. Once the curing is done, pressure inside the autoclave gets released
through v4 and the cap will be opened.
Fig.2 Schematic diagram
3.1 PLC based curing system
In this project we use GE FanucVersaMax Nano PLC IC200NDD101 has six 24Vdc inputs and
four DC transistor outputs. It uses +24Vdc nominal input power for PLC operation. The four
transistor output circuits can be used to switch devices like valves, lamps or contactors. External
fusing should be provided to protect the outputs. Fast fuses are recommended. The outputs can be
configured as regular outputs or as outputs controlled by the High-Speed Counters. Then can also be
used as Pulse Train and/or Pulse Width Modulation (PWM) outputs. All outputs are isolated between
field and logic and are switching positive voltage. The outputs have one common incoming supply
(VC) and one common ground (COM). The outputs are able to drive high inrush currents (8 times
the rated current) and are protected against negative voltage pulses. This makes it possible to switch
lamps and inductive loads.
Fig.3 Block diagram Fig.4 PLC system
The sequence of processes in curing is achieved as follows
� Before passing the steam into line, pressure range will be checked.
� An indication will be given to operator if the pressure range is low.
� Once when the pressure satisfies the set point the proximity senses the presence of mould.
� When proximity sensor sense the metal mould, a period of 5 seconds will be considered as
loading time.
1st International Conference on New Scientific Creations in Engineering and Technology (ICNSCET-19)
International Journal of Recent Trends in Engineering & Research (IJRTER)
Special Issue; March - 2019 [ISSN: 2455-1457]
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� After the cap gets closed, steam will be allowed through autoclave.
Here the temperature of the steam is checked. Once the temperature range satisfies the set point
the process will be continued, else the process will be held unless the required temperature
attains. After the curing time over, the excess steam in autoclave is released to atmosphere and
the cap will be opened.
FIG. 5 FLOW CHART
3.2 Simulation and results
1st International Conference on New Scientific Creations in Engineering and Technology (ICNSCET-19)
International Journal of Recent Trends in Engineering & Research (IJRTER)
Special Issue; March - 2019 [ISSN: 2455-1457]
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Fig.6 Ladder diagram
TABLLE 1 ADDRESSING
3.2.1 Description
%I0001 is an address proximity switch. When the proximity sense the mould, control signal
flows to the valves. %I0002 is an low pressure switch, if it is high it does not allows the steam inside
autoclave and indicates the pressure is low. %I0003 is a thermostat switch, it is high when the
temperature is high. The coil %Q0002,%Q0003,%Q0004 are connected to solenoids, they are
switched to ‘high’ or ‘low’ depends upon the control signal from PLC.%Q0001 Is the address of
push pull solenoid used for opening or closing the autoclave’s cap. Simulation is not possible in GE
Fanuc .so we use Schneider product simulation software.
From the Fig 6 the ladder diagram shows the overall process involved in the project. Here, inputs are
called as contacts and the outputs are called as coils.
Initially the coil Q3 is energized. when the proximity sense the mould , timersT1&T4 is ON. The
preset value of the timer T1 is 10sec which is the loading and unloading time for mould. Preset value
timer T4 is 5sec which is the time delay for autoclave cap closing.
IV CONCLUSION The proposed method of curing process automation was done using PLC and VersaPro software.
It can reduce or eliminate the manpower in the process of V-belt curing. Our research idea
specifically designed for Veegrip Belts Pvt Ltd. We hope the proposed idea can make a great change
in that process and can give a benefit of reducing the manpower, operating cost and improve the
accuracy.This method of curing the belt by automation will provide more accurate result on its
process and production. This helps in maintain the shift 24/7 with regular interval. Although the PLC
is a programmable one , any modification in future process can be made easier.An overall labor cost
can be minimized and helps in improving the quality of the belt because there won’t be any human
error. This process doesn’t any involve any harmful chemical reaction so it is an eco-friendly
process.
REFERENCES
[1]. Ma Shuying, C. Lidong, Shi Lei, Liu Shengtao, Z. Liang, L. Shiguang, “Design of the temperature control system of
solar cell lamination machine”, IEEE, pp. 506-509, Vol. 3, 2010.
[2]. S. Kalaivani, M. Jagadeeswari, “PLC and SCADA Based Effective Boiler Automation System for Thermal Power
Plant”, International journal of advanced research in computer engineering & technology, pp. 1653-1657, Vol. 4, Issue 4,
April 2015.
OUTPUT SYMBOL
Push pull solenoid %Q0001
Solenoid valve 1 %Q0002
solenoid valve 2 %Q0003
Solenoid valve 3 %Q0004
INPUT SYMBOL
Proximity sensor %I0001
Thermostat %I0002
Low pressure switch %I0003
1st International Conference on New Scientific Creations in Engineering and Technology (ICNSCET-19)
International Journal of Recent Trends in Engineering & Research (IJRTER)
Special Issue; March - 2019 [ISSN: 2455-1457]
@IJRTER-2019, All Rights Reserved 355
[3]. S. Das, S. Dutta, A. Sarkar, S. Kar, “Recognition and Disposal of Faulty Bottles in a Bottle Filling Industry Using
PLC and Producing Human Machine Interface by SCADA”, International Refereed Journal of Engineering and Science
(IRJES), pp. 18-23, ISSN 2319-183X, Volume 3, Issue 5, May 2014.
[4]. K. Ali, R. Ghoni, A. N. Abdalla, “Advanced Control of Hybrid-PLC System”, International conference on modelling
optimization and computing, pp. 218-225, ISSN 1877-7058, June 2012.
[5] Lu Jinyan,Mu Wei and Li Lezhong,vol.36.pp. 46-73,Nov 2006
[6]. Maria G. Ioannides, “Design and Implementation of PLC-Based Monitoring Control System for Induction Motor”,
IEEE transactions on energy conversion, pp. 469-476, ISSN 0885-8969, Vol. 19, No. 3, Sept. 2004.