PLC Based Smart And Secure Cement Filling And Packaging Plant
With a continuous search, trials experiments and visiting of cement industry, now we come out with a total dispatched automation solution of Smart & Secure Cement Filing & Packaging Plant for cement industries under the supervision of Engr. Mohammad Tahir Iqbal. The automation starts
2025-06-28 16:34:30 - Adil Khan
PLC Based Smart And Secure Cement Filling And Packaging Plant
Project Area of Specialization Augmented and Virtual RealityProject SummaryWith a continuous search, trials experiments and visiting of cement industry, now we come out with a total dispatched automation solution of Smart & Secure Cement Filing & Packaging Plant for cement industries under the supervision of Engr. Mohammad Tahir Iqbal.
The automation starts from gate in to gate out of the vehicle.
The vehicle is provided with a radio frequency Identification card (RFID card) and this card is pasted at the front window glass of the vehicle.
The RFID card is sensed and vehicle detail is send to PC. The in time of the truck is logged into data base, time monitoring starts from now.
Then the vehicle goes to the weight bridge, the vehicle weight is stored and set automatically to record the weight of the truck at the entry time.
After the weight bridge we have an automatic filling unit zone. In filling unit the cement bag is placed on the load cell. When the bag is filled to required weight, it is pushed to conveyor belt through a pusher mechanism.
A proximity sensor is mounted on the conveyor belt, used for counting the bags and starts the conveyor belt.
After that we have a sorting and counting zone.in this zone a camera is mounted on conveyor belt for damage and true bags detection. If the target bag is damaged, then the pusher mechanism throw the bag out from conveyor belt. If the bag is true then the conveyor motor starts and the proximity sensor counts the bag.
Project Objectives- RFID based detection of vehicles
- Vehicles weight and enter/exit time log
- Automatic filling and packaging of cement bags
- Detection of damaged bags by image processing on MATLAB
- Counting of damaged and required bags and storage of cement bags
- Handle the plant operations at remote locations using SCADA
First of all we start with radio frequency identification of vehicles at the entry gate. Basically the concept which we used is RFID master card and slave card. When the slave card (vehicle) try to access the entry gate. The RFID module (MFRC522) will take the slave card as invalid (unauthorized vehicle) and will not allow it to open the gate barrier. The vehicle will authorized only when the master card will add the slave card in RFID module to make it valid (authorized vehicle). Enter/exit time log of the vehicle will be stored at run time.
When the vehicle is on the weight bridge, the load cell measures the weight of vehicle and PLC sends data to PC to store weight of the vehicle.
When the bag is placed at load cell (filling unit), PLC starts the filler motor and material is filled in bag up to the specific weight, PLC stops the filler motor and starts the pusher mechanism to throw the bags onto the conveyor belt. Proximity sensor send the signal to PLC and it starts counting of bags and run the conveyor belt.
Proximity sensor (damaged bag detection zone) will send the signal to PLC and it stops the conveyor belt. Camera is mounted on conveyor belt, it takes the images of bag. These images are processed on MATLAB. If the bag is damaged the PLC starts the pusher mechanism to throw the bag in damage bag zone. Otherwise the PLC starts the conveyor belt to count and store the bag in the storage zone.
To handle the plant operations at remote locations we use SCADA. Enter/exit time log and weight of the vehicle will be displayed here. We can read real time data (sensor values), means we can monitor exactly the things happening in the field and data acquisition of the sensor values.
Benefits of the Project- Our Project plays significant role in the field of control and automation of the packing plant to easily manage
- This enables it to make adjustments to the process more frequently and reliably than a human operator can
- Advanced machine for automatically placing various type of empty bags on packers with speed and accuracy
- Significant increase of safety level, only authorized vehicles can enter in industry through the gate, un authorized vehicles will be blocked at the entry gate, loss of un accountant bags, damage bags, stealing of cement by workers and truck drivers will be minimized
- With the development of this project, it will significantly reduce the labor cost
- It will respond faster and more effectively to changes
- It will efficiently improves the performance and productivity of plant in the manufacturing industry by more efficient use of materials
- It would reduce the man made errors and uses different control mechanism or tools for handling various processes within a manufacturing unit
- Equipment for filling bulk cement from silos into bags with high weight accuracy using load cell
- Mechanical hardware with sensor interfacing
- Pusher mechanism and conveyor belt using DC geared motors
- Vehicles weight and enter/exit time log
- RFID based authorized vehicles access
- Automated filling and packing of bags
- Identification of damaged and true bags using MATLAB image processing
- Counting of damaged and required bags and storage of cement bags
- Handle the plant operations at remote locations using SCADA
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 78559 | |||
| PLC S7-200 CPU 224xp | Equipment | 1 | 30000 | 30000 |
| RFID Card Module | Equipment | 1 | 1200 | 1200 |
| Web Camera | Equipment | 1 | 2000 | 2000 |
| DC geared motors | Equipment | 4 | 1000 | 4000 |
| DC Window motor | Equipment | 1 | 2000 | 2000 |
| Proximity Sensor | Equipment | 3 | 900 | 2700 |
| Load Cell | Equipment | 2 | 1000 | 2000 |
| Arduino | Equipment | 2 | 1500 | 3000 |
| Push Buttons (PLC) | Equipment | 10 | 120 | 1200 |
| Light Indicators (PLC) | Equipment | 10 | 70 | 700 |
| Relay Modules | Equipment | 8 | 120 | 960 |
| Output Relays | Equipment | 10 | 215 | 2150 |
| Conveyor Belt | Equipment | 1 | 7989 | 7989 |
| Mechanical Hardware | Equipment | 1 | 10000 | 10000 |
| Customized Cement Bags | Miscellaneous | 18 | 120 | 2160 |
| Power supplies | Miscellaneous | 2 | 1000 | 2000 |
| Circuitry (wires) | Miscellaneous | 1 | 1500 | 1500 |
| Printing | Miscellaneous | 1 | 500 | 500 |
| Transportation | Miscellaneous | 1 | 2500 | 2500 |