Automatic Control of a Belt Weigh-feeder

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Project Title

Automatic Control of a Belt Weigh-feeder

Project Area of Specialization

Robotics

Project Summary

This project comprises of a prototype which is designed to automize the control of a Belt Weigh-Feeder and is the replica of cement industry Belt Weigh-Feeder mechanism. This control system is specifically purposed to regulate the speed of converyor belt according to the mechanical load (crushes, gypsum etc.) which it is bearing, so that the desired mass flow rate is constantly achieved in real time at the end of belt where load is being collected. This mass flow rate is the actual representation of the factor which tells that how much load is flowing on the belt over a specific period of time. In any industry, this mass flow rate holds very much importance in terms of its regulation so that overall process related to that mass load, remains well synchronized and timely achieved. The prime purpose of this project is to achieve that real time constant value of desired mass flow rate. This project is a Software plus Hardware based prototype.

Project Objectives

The major objectives of this project are as follows:

1. To get the desired mass flow rate in real time.
2. To automate the speed regulation mechanism of Belt Weigh Feeder, according to the load flowing on it.
3. To implement Fuzzy logic along with PID controller mechanism.

Project Implementation Method

The methodology of this project has been divided into following steps: (steps are being summarized here)

1. At first, designing a small scale prototype of Belt Weigh Feeder which is the actual replica of cement industry Weigh Feeder mechanism.
 
2. After designing the prototype, selecting a variable DC motor (at small scale DC motor use is feasible) along with selection of suitable gear ratio for the gear box which is being coupled to DC motor which provides stability to the conveyor belt pulleys, and also helps to set a fixed range of speed of shaft, on which the belt is attached.

(Microcontroller Arduino UNO R3 was selected for software and hardware interfacing. The programming is being done on Arduino IDE. All of following steps are being completed, or to be completed, while using Arduino.)

3. Then, using rotatory encoder, verifying the speed range of shaft which is connected to gear box being coupled with DC motor, using variation in voltage which is supplied to DC motor.

4. Then, measuring the load flowing on the belt with the help of load cell sensor module.

5. Then using Motor Bridge Module, getting the speed of motor varied by the continuous changing in PWM via Arduino.

6. Then using the values obtained in steps 3 and 4, getting the real time mass flow rate.

7. After step 6, for achieving the desired mass flow rate, using MATLAB, implementing Fuzzy logic plus PID Controller mechanism so that whenever the actual mass flow rate reaches a value different than that of desired one, the PWM supplied to the Motor via Motor Bridge Module and Arduino are varied accordingly so that our purpose is being achieved. Like, if there is some error (actual mass flow rate is less or more than the desired one), then this error being removed by Fuzzy and PID controller combination.

Benefits of the Project

In many industries, Belt Weigh Feeder setup is being automized through PLC Scada systems which are way more complex and expensive. Because of their complexity, they require maintenance and regular check and balance. Also the skillful staff is required for managing PLC Scada systems and this requires a lot of budget. This prototype is designed on the basis of cement industry Weigh Feeder mechanism, and it provides much more economcial and cost effective setup which can easily be maintained and in case of any technical problem, that problem can easily be sorted out. This design can be further modified to implement it into cement industries which will provide a much better solution and a replacement to PLC scada systems.

Technical Details of Final Deliverable

The final deliverable consists of automized prototype which will provide desired value of mass flow rate in real time monitoring system. Like, if the load being dropped from the hopper, is having more mass value than speed of the motor is being minimized, and vice versa. This design can be further modified for implementing it in the cement industries for being a better replacement than the expensive PLC scada systems.

Final Deliverable of the Project

HW/SW integrated system

Type of Industry

Manufacturing

Technologies

Robotics

Sustainable Development Goals

Decent Work and Economic Growth, Responsible Consumption and Production

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com