conveyor belt system control

conveyor system - motion control application

conveyor system - motion control application

For conveyor belt applications Oriental Motor offers a wide range options. For fixed or constant speed applications, AC motors & gear motors are well suited. For applications where speed control, higher speeds or maximum torque in a small area may be needed, the AC & brushless DC motor speed control systems can be used. For precise positioning Oriental Motor's stepper or servo motor packages are ideal.

For system solutions requiring connection to an upper level controller, PLC or HMI, Oriental Motor offers several networked products to allow for easy control using I/O or RS-485 / Modbus (RTU) networks. Our AC & brushless DC motor speed control systems also simply and easily connect to upper level controls.

AC induction motorsare ideal for conveyor systems that operate continuously in one direction. For conveyor systems where the load must be held in place or for vertical applications, there are a wide range ofAC motors with power-off activated electromagnetic brake. For simple braking, ourAC Speed Control MotorsorBrake Packare also convenient options. TheIP67 rated washdown AC induction motorsare suitable for conveyors that will be in contact with water or need to be washed. Synchronous motors are also available for conveyors where the motor needs to be operated continuously in one direction at synchronous speed regardless of load torque; thelow-speed synchronous motor is idealfor frequent starting, stopping and reversing.

Low-Speed Synchronous Motorsare suitable for applications where the motor is operated starting, stopping and reversing repeatedly and the motor is operated at synchronous speed regardless of load torque.

Right-Angle Gearheads are suitable for applications where space saving is required by allowing the motor to be mounted at a right-angle to the conveyor. Solid shaft and hollow shaft models are available.

For conveyors where the speed needs to controlled or vary during operation Oriental Motor offers easy-to-useAC Speed Control Motorsas well asBrushless DC Motors & Gear Motors (BLDC Motors)that offer a wide speed control range and constant torque regardless of load.

By combining a control circuit with the motor, speed changes can be performed. Speed control motors are optimal for switching between high speed and low speed operation and for arbitrary adjustment of speed.

Brushless DC Motors & Gear Motors (BLDC Motors)provide high speed stability, energy saving and space saving. Brushless DC motors also allow for stable speed control even with a fluctuating load and offer constant torque over a wide speed range.

AC Speed Control Motorsallow for simple settings and basic speed control functions using an AC Motor. Inverters are control circuits that control the power supply frequency and voltage applied to three-phase induction motors in order to control speed.

AC speed control motors are motors that include an induction or reversible motor equipped with a tachogenerator (AC generator) for speed detection. By combining these motors with a dedicated control circuit, speed changes can be performed.

Direct connection to the drive shaft is possible without using a connecting part which enables equipment space saving. In addition, the hollow shaft flat gearhead enables permissible torque without saturation even at high gear ratios, so the motor torque can be fully utilized.

Right-Angle Gearheads are suitable for applications where space saving is required by allowing the motor to be mounted at a right-angle to the conveyor. Solid shaft and hollow shaft models are available

For conveyors that require higher accuracy positioning Oriental Motor offers a wide range ofStepper MotorandServo Motorsolutions. Stepper motors, with their ability to product high torque at a low speed while minimizing vibration, are ideal for applications requiring quick positioning over a short distance. Servo motors are easy to operate and allow for smooth operation with large inertial loads and belt mechanisms. Servo motors are ideal for positioning over long distances using a flat torque characteristic from low to high speeds.

Stepper Motorsare suitable for high accuracy positioning over a short distance and provide high torque even at low speeds. Stepper motors also offer very low vibration and a wide range of features and options such as gearheads, encoders and built-in controllers to meet the specific needs of your application.

Servo Motorsprovide accurate positioning for quick moves or for a long distance moves. All feature a closed loop configuration ideal for variable loads and offer a wide range of gear options and braking or load holding options. The built-in controller (stored data) FLEX also helps for system configuration considerations.

Oriental Motor offersNetwork productsunder the FLEX concept, meaning each product is equipped with an interface that connects to various master controllers featuringI/O, RS-485 / Modbus (RTU) or Factory Automation. Networked products enable operating data and parameters for each motor to be set at a Master Controller and sent to each driver. In addition, operation commands can be input send set using various communication methods to meet the need of a wide range of available Network Solutions.

2. RS-485 / Modbus (RTU) - Operating data and parameters can be set and operation commands can be input using RS-485 communication. Up to 31 drivers can be connected to each serial communication module. Also there is a function that enables the simultaneous start of multiple axes. The protocol supports Modbus (RTU), enable connection with devices such as a touch screen (HMI) or PCs.

3. Factory Automation Network - Use of a network converter (sold separately) enables support with CC-Link, MECHATROLINK or EtherCAT communication. Operating data and parameters can be set and operation commands can be input using various communication methods.

The communication protocol of the master controller, Factory Automation (FA) network, is converted to Oriental Motor's own RS-485 communication protocol. Connection to FLEX-compatible products is completed with one RS-485 communication cable.

belt position control systems | erhardt+leimer

belt position control systems | erhardt+leimer

Belt guiders eliminate errors such as soiling, varying belt load, misaligned rollers and temperature fluctuations. In addition, they guarantee a constant belt position during the production process. Two different control systems are used for belt position control: Continuous controllers or three-point controllers.

Rollers that are at an angle to the direction of belt travel cause the belt to move laterally. This principle is used by the pivoting roller systems ELBANDER for belt control. The pivot point for the pivoting roller is one of the two bearings at the ends. The positioning roller is positioned at an angle around this point depending on the correction required.

On conveyor belts, the pivoting roller is mounted on the bottom run just ahead of the lock roller. The actuator is to be arranged at an angle of 15 to the direction of travel of the belt. The actuating movement must be at the angle bisector between the infeed and outfeed path. The infeed path should be at least one belt width. The outfeed path is to be kept as short as possible. The wrapping around the positioning roller should be between 40 and 60. For production speeds >1000 m/min, the wrapping should be reduced to 10 - 20. The position is measured using an edge sensor immediately before the positioning roller. To prevent possible interference from the stretch roller on the web control system, this roller is only allowed to be positioned with its axis parallel.

A = Belt tension distribution at the infeed | B = Belt tension distribution at the outfeed |K = Correction of the belt position | = Correction angle| 1 = Basic belt tension| 2 = Tension distribution on actuating movement to left | 3 = Tension distribution on actuating movement to right | 1 = Pivot point |2 = Infeed roller| 3 = Positioning roller| 4 = Sensor | 5 = Locking roller| L1 = Infeed path | L2 = Outfeed path | AB = Operating width

Web guidance rollers that are at an angle to the direction of belt travel cause the belt to move laterally. This principle is used by the pivoting roller systems ELBANDER for belt control. The pivot point for the pivoting roller is one of the two bearings at the ends. The positioning roller is positioned at an angle around this point depending on the correction required.

With belt position control of conveyor belts, the pivoting roller is mounted on the bottom run just ahead of the lock roller. The actuator must be arranged parallel to the belt direction of movement, whereby the actuating movement must be at the angle bisector between the infeed and outfeed path. Note that the infeed length should be at least one belt width, and the outfeed length should be kept as short as possible. The wrapping around the positioning roller should be between 40 and 60. If the production speed is > 1000 m/min, then the wrapping should be reduced to 10 to 20. Exact position measurement is performed using an edge sensor, which is attached immediately after the positioning roller. To prevent possible interference from the stretch roller on the belt control system, this roller is only allowed to be positioned with its axis parallel.

A = Belt tension distribution at the infeed | B = Belt tension distribution at the outfeed | K = Correction of the belt position | = Correction angle| 1 = Basic belt tension | 2 = Tension distribution on actuating movement to left | 3 = Tension distribution on actuating movement to right| 1 = Pivot point | 2 = Infeed roller| 3 = Positioning roller| 4 = Sensor| 5 = Locking roller| L1 = Infeed path | L2 = Outfeed path| AB = Operating width |

key benefits of a conveyor control system

key benefits of a conveyor control system

Think of your conveyor system as a body. You have good bones, but you need a smart brain. Thats why you need a strong conveyor control. When you enable system integration with your host computer (or other software systems) you have an optimized, holistic system thats engineered to evolve alongside you.

The right conveyor control saves time, money and efficiency. It will optimize your material handling systems and warehouse operations. It will allow for variable production rates and quick production changes. Programmable Logic Controls (PLC) allow for this necessary direct system control. This centralized network-oriented approach is best primed for automation and attaining the numbers you need to thrive.

You also need a system with intuitive operator interfaces that collects, views, stores, controls, analyzes, and manages conveyor information from the facility floor in real-time. This makes it easy for a project manager to interpret and implement changes or repairs on your productions lines. When operators and maintenance workers dont have to take as much time troubleshooting, when they have a smart conveyor control that helps process, diagnose and debug issues quickly, it ensures your potential downtime is not your downfall.

The right conveyor control allows for built-in adaptation. Your controls should be expandable and flexible to improve workflow and meet new requirements and accommodate for additions and adaptations as you grow and generate more order fulfillment.

A smart system control software even saves lives. A conveyor control should have smart motor controllers to stop your conveyor belt in the event of emergency. It should automatically shut down the system in the case of malfunction, because any breach of protocol could not only harm your bottom line it could potentially harm any worker on the line.

At Richards-Wilcox Conveyor, we specialize in conveyor systems design. Weve designed conveyor systems for every size and scope of facility. We understand your factory, learn its unique needs, and know what it needs to be future-ready. We optimize your level controller, belt tension, motion control, flat belt, and material handling equipment.

Its essential to make your conveyor design optimized to your own space. Its why our applications include the execution of conveyor simulations computer-generated models to check how a conveyor system will work, before its ever built. The right conveyor control can even create these kinds of simulations to help evaluate new ideas for optimization.

We understand your factory, learn its unique needs, and know what it needs for the future. But whether were exploring a new system designed from scratch or testing out proposed modifications to an existing system, the right conveyor control makes it all click. Thats what really makes you engineered for evolution.

conveyor belt controller

conveyor belt controller

In almost all the manufacturing industries where ever there is complete assembly line automation like bottling plant, chemical industries, food processing and packaging industries a conveyor belt is ultimate and widely used option. The entire process iscarried on single (or multiple)conveyor belt(s). From start to end the items are moving on belt and the processes are done in between, while they are moving.

Just take an example of any bottling plant then in this case the bottles are moving on belt one by one and at one place they are filled, atanother place they are sealed, then labeling and finely packaging in a bunch on 10, 20 or 50 likewise. This whole processruns on single conveyor belt.

So here I am explaining one such conveyor belt application. I amtaking simulated conveyor belt from multisim 10.0 software to explain this application. In this example at a time only one box moves on belt it is filled with items at the middle of belt and then it movesforward. When it passes through beltanother box is available for filling. So actually its very simple application and it illustrate the demo of actual conveyor belt.

Because this very small system we dont require more input output pins. So we are using 20 pin 89C2051 micro controllers. As shown in figure there are inverters, buffers, indicators and a 2 digit counter, the building blocks of the system 89C2051 it performs following tasks. It controls the belt motor by giving fwd and stp pulses. Also it gives drop command to fill the container. It counts no of items in container and resets the counter with every new container. Indicates different actions on LEDs Inverters it inverters the positive pulses into negative pulses Buffers it provides isolation between digital system (micro controller)and analog system (conveyor belt) 2 digit counters it counts no of items filled in container up to 99 only LED indicators it indicates various events currently going on Conveyor Belt Controller Circuit Connections & Operation Connections: as shown in circuit tab 1 two ports of 89C2051 P1 & P3 controls entire system. Pins P1.0, P1.1, P1.2 are connected to fwd, stop and drop controls through buffers 7407. P1.5, P1.6 & P1.7 drives 3 LEDs as shown. So P1 is completely output port. All four sensor outputs are connected with P3 pins P3.2, P3.4, P3.5 & P3.7 through inverters 74LS04. One LED indicator is also connected with each output. Pin P3.0 is connected with reset input of counter. Also the sensor 4 output is directly connected with clock signal of counter. A 12 MHz crystal along with 2 33 pf capacitors is connected with XTAL pins to provide clock signal. A push button switch along with capacitor C1 forms power on reset circuit. Above figure shows 2 digit counter using CMOS chip CD4026, that is counter cum 7 segment display driver. Its outputs can be directly connected to common cathode type 7 seven segment display. As shown in figure the clock signalfrom sensor 4 is given to chip U3. Its carry out signal is connected with clock signal of chip U1. Clock inhibit signal (INH)of both chipsare tied to Gnd and display enable signals (DEI)are tied to Vcc. The master reset (MR) of both chips is connected with reset output from 89C2051. Operation:- Controller will apply fwd pulse to motor and motor will start rotating At the same time one timer is started. Container will move forward and this is indicated by D1 As container passes through sensor 1 the timer is reset As a container reaches to sensor 2 immediately stop pulse is applied and container is stop. D2 glows to indicates this event Now the drop signal is made high to drop items from nozzle to container. The counter will display the count and counter will count no of items. It will count 50 items Now again fwd pulse is applied. As container reaches to sensor 4. Again motor is stopped for 3 sec Again this cycle repeats Now if there is no container on belt. There is no output from sensor 1. So timer overflows and that means there will be no more containers to be filled. So motor will be automatically stopped. Software Program Software program: Software program is very simple that is written in C language and compiled using KIEL (ODE) cross compiler. Along with main function entire program is a combination of 5 different functions. Delay function generates random fix amount delay (<10 ms) to provide pulse to LEDs Bigly function generates fix amount delay of2 sec to hold the conveyor belt when container reaches sensor 4 positions Mildly function is again random fix amount delay (<1 ms) provided in between two item counts. Timer function is interrupt enabled function and it is called automatically when timer overflows from all 1s to all 0s. It is called after every 50 ms. It increases the count (b) and calculate up to 200. If this count is reached that means total 10 sec delay is over then it will apply stop pulse and stop rotating motor and belt Interrupt function is also interrupt enabled function and it is called when the container passes through it. It just resets the count (b) every time as containers are passing through belt. Main function performs following tasks Initializes ports, timer and enables interrupts Then it applies start pulse to motor and reset pulse to counter Indicates motor is running on LED Waits for container to reach at sensor 2. When it reaches stops the motor Now it applies high logic to drop pin to drop item into container Counts number of items to 50. And then stops dropping items. Again applies start pulse to motor and now waits for o/p from sensor 3 As container reaches to sensor 3 position sends stop pulse After 2 sec again the same above cycle repeats. Project Source Code### #includesbit strt = P1^0;// defining port pinssbit stp = P1^1;sbit drop = P1^2;sbit led1 = P1^7;sbit led2 = P1^6;sbit led3 = P1^5;sbit obj = P3^4;sbit cntr = P3^5;sbit end = P3^7;sbit rst = P3^0;unsigned int c=0,b=0;void main() { P1=0x00;// P1 as output portP3=0xFE; // P3 as input portTMOD=0x01; // timer initilizationTL0 = 0xAF; // load timer vlaueTH0 = 0x3C;TR0 = 1; // start timerIE=0x83; // enable timer and external interruptback:strt = 1;// apply start pulse to motorrst=1; // and reset pulse to 2 digit counterdelay();strt = 0;rst=0;led1 = 1; // indicate on LEDsled2=0;while(obj==1); // wait until sensor 2 outputstp = 1; // apply stop pulse to motordelay();stp = 0;led1=0; // indicate on LEDsled2=1;drop = 1; // start dropping itemsled3=1;cnt:while(cntr==1);smldely();c++; // count no of itemscntr=1;if(c<50) goto cnt; // till it is 50drop=0; // stop dropping itemsled3=0;strt = 1; // start motordelay();strt = 0;led2=0;led1 = 1;while(end==1); // wait until sensor 3 outputstp = 1; // apply stop pulse againrst=1;delay();stp = 0;rst=0;led1=0;led2=1;bigdely(); // wait for 2 secondobj=1;end=1;EA=1;goto back; // again start process }###Circuit Diagramsflat-belt-3 Filed Under: Electronic ProjectsTagged With: 89c2051, conveyor belt, microcontroller

Because this very small system we dont require more input output pins. So we are using 20 pin 89C2051 micro controllers. As shown in figure there are inverters, buffers, indicators and a 2 digit counter, the building blocks of the system

Connections: as shown in circuit tab 1 two ports of 89C2051 P1 & P3 controls entire system. Pins P1.0, P1.1, P1.2 are connected to fwd, stop and drop controls through buffers 7407. P1.5, P1.6 & P1.7 drives 3 LEDs as shown. So P1 is completely output port. All four sensor outputs are connected with P3 pins P3.2, P3.4, P3.5 & P3.7 through inverters 74LS04. One LED indicator is also connected with each output. Pin P3.0 is connected with reset input of counter. Also the sensor 4 output is directly connected with clock signal of counter. A 12 MHz crystal along with 2 33 pf capacitors is connected with XTAL pins to provide clock signal. A push button switch along with capacitor C1 forms power on reset circuit.

Above figure shows 2 digit counter using CMOS chip CD4026, that is counter cum 7 segment display driver. Its outputs can be directly connected to common cathode type 7 seven segment display. As shown in figure the clock signalfrom sensor 4 is given to chip U3. Its carry out signal is connected with clock signal of chip U1. Clock inhibit signal (INH)of both chipsare tied to Gnd and display enable signals (DEI)are tied to Vcc. The master reset (MR) of both chips is connected with reset output from 89C2051.

Timer function is interrupt enabled function and it is called automatically when timer overflows from all 1s to all 0s. It is called after every 50 ms. It increases the count (b) and calculate up to 200. If this count is reached that means total 10 sec delay is over then it will apply stop pulse and stop rotating motor and belt

sbit strt = P1^0;// defining port pinssbit stp = P1^1;sbit drop = P1^2;sbit led1 = P1^7;sbit led2 = P1^6;sbit led3 = P1^5;sbit obj = P3^4;sbit cntr = P3^5;sbit end = P3^7;sbit rst = P3^0;unsigned int c=0,b=0;

void main() { P1=0x00;// P1 as output portP3=0xFE; // P3 as input portTMOD=0x01; // timer initilizationTL0 = 0xAF; // load timer vlaueTH0 = 0x3C;TR0 = 1; // start timerIE=0x83; // enable timer and external interruptback:strt = 1;// apply start pulse to motorrst=1; // and reset pulse to 2 digit counterdelay();strt = 0;rst=0;led1 = 1; // indicate on LEDsled2=0;while(obj==1); // wait until sensor 2 outputstp = 1; // apply stop pulse to motordelay();stp = 0;led1=0; // indicate on LEDsled2=1;drop = 1; // start dropping itemsled3=1;cnt:while(cntr==1);smldely();c++; // count no of itemscntr=1;if(c<50) goto cnt; // till it is 50drop=0; // stop dropping itemsled3=0;strt = 1; // start motordelay();strt = 0;led2=0;led1 = 1;while(end==1); // wait until sensor 3 outputstp = 1; // apply stop pulse againrst=1;delay();stp = 0;rst=0;led1=0;led2=1;bigdely(); // wait for 2 secondobj=1;end=1;EA=1;goto back; // again start process

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