IJSRD - International Journal for Scientific Research & Development| Vol.

5, Issue 06, 2017 | ISSN (online): 2321-0613

Development of PLC based Automatic Prototype Cutting Machine

Harshitha R1 Dr. M. S. Srinath2
1
PG Student 2Professor
1,2
Department of Industrial Automation Engineering
1,2
Malnad College of Engineering, Hassan, India
Abstract— Cutting is a compressive and shearing specify or select them when setting up the machining
phenomenon, where cutting a materials like paper, timber, process. Several input variables are described below.
pipes to the required length in any manufacturing industry is
A. Background and Motivation
the initial step. Increasing in Global competition and
technological advances are forcing manufactures designers If cutting is carried out at the design stage the manufacturing
and engineers rapidly produce strategies decreasing products engineer has higher probability of making the best usage of
development cost and time. Manufactures who exit at a the materials. To get maximum benefits in material cost
same time have the option of selecting optimum reduction and lead time reduction automation of process is
technologies or processes to coincide with their required. Cutting is the part of design process and
manufacturing surrounding. The main idea of this work is to Programmable Logic Controller (PLC) and Human Machine
design a prototype model for automating the cutting process Interface (HMI) is used to control the cutting process which
for varying length in continuous cutting process with is main part of the manufacturing industries. Each and every
reduced time and cost which may applicable in industry. part of the design that leads to the final cost is examined,
Programmable Logic controller (PLC) and Human Machine and appropriate remedies are taken to prevent to those
Interface (HMI) is used to propose new approach, HMI is unwanted and expensive elements before it approach to the
designed to enter the values like length, rpm, number of final designs.
counts and HMI is connected to PLC by RS485 serial B. Automation of Manufacturing Process
communication protocol. PLC is programmed to control the
Automation or programmed control is the utilization of
servo motor where entered values are converted to pulses
and when targeted length is reached PLC will actuate different control frameworks for operating equipments such
pneumatic press to cut the paper to solve the problem of as machineries and processes in factories with negligible or
decreased human intercession. Some process have been
continuous cutting process for varying length.
completely automated some semi-automated, the biggest
Key words: HMI, PLC, RS485
advantage automation is to save labors time, save energy
and materials and to improved quality, accuracy and
I. INTRODUCTION
precision. This work aims to guide the increased accuracy
The word manufacturing may have coined recently but the and precision of the paper cutting profile where paper is cut
process of manufacturing is there since the inception of to exact length and number of counts which is achieved by
technology. Cost reduction seems to be today’s new way of programmable logic control (PLC).
approach in the manufacturing community. The total
product cost is influenced by two major elements i.e. II. BLOCK DIAGRAM
Material and manufacturing cost. In any manufacturing
industry cutting is usually used to fit several components of
large size to most favorable material standard sizes. A shift
growth in recent modernization and automation of
manufacturing technology has urged an accurate and
economical system to give a perfect finish to the product
developed.
Machining is a term that covers a large collection
of manufacturing processes designed to remove unwanted Fig. 1: Block diagram
material, usually in the form of chips, from a work-piece. This part of the report explains in detail about cutting
Machining is used to convert castings, forgings, or process which has been designed assembled, powered,
preformed blocks of metal into desired shapes, with size and programmed and analyzed. The emphasis is given to core
finish specified to fulfill design requirements. Almost every principles involved in running the machine. Cutting refers to
manufactured product has components that require the process of deposit cutting patterns to minimize the raw
machining, often to great precision. The majority of material size like sheet metal and paper etc. Several
industrial applications of machining are in metals. Although approaches in controlling and synchronization have also
the metal cutting process has resisted theoretical analysis been put forward. The control system has been used
because of its complexity, the application of these processes effectively during the process.
in the industrial world is widespread. Metal cutting Any process or system or event can be explained in
processes can be viewed as consisting of independent input many perspectives as such it has been tried to explain the
variables, dependent variables, and independent dependent working of cutting process in mechanical and electrical as
interactions or relationships. The engineer or machine tool two perspectives. Mechanical perspective of design
operator has direct control over the input variables and can describes the system as it can be seen or physically
experienced. An electrical perspective of design explains the

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 Development of PLC based Automatic Prototype Cutting Machine
(IJSRD/Vol. 5/Issue 06/2017/019)

background activity of system i.e., between its input and and u stands for transistor which produces high speed. It
output. The proposed prototype model is as shown in the shows the architecture how PLC connected to HMI and
block diagram [Fig 1]. The major components required in servo motors. HMI is connected through serial link RS485.
the present model are HMI, PLC, servo drive, servo motor, Programming for this PLC is done using SoMachine Basic
and pneumatic actuator. software using ladder diagram and installed to PLC using
USB key or Ethernet.
III. HARDWARE IMPLEMENTATION
C. Motor Synchronization
A. Human Machine Interface HMI A servo drive is a unique electronic enhancer used to control
Human Machine Interface is a high performance touch electric servo components. A servo drive monitors the
performance touch screen machine control interface for feedback signal from the servomechanism and consistently
industrial application and also acts as an interface between modifies for deviation from expected behavior.
human and machine. HMI is designed to reach the rapidly A servo motor is a rotating actuator or direct actuator that
increasing difficult process of the machines and systems. takes into account exact control of angular or straight
HMI is designed to reach the specific Human Machine position, velocity and acceleration. It comprises of an
Interface needs with the help of open and standardized appropriate motor coupled to a sensor for position input.
interface in hardware and software, which allows in the The motors are driven by frequency converter, which takes
perfect merge into the automation systems. signals from PLC controller. The speed and position of
HMI Human Machine Interface is designed and length to cut is given directly by HMI. The values entered
installed through the software called vijeo design software. by HMI are the input to the PLC where the given values are
HMI is connected to PLC through connection bus called as converted to the pulses at output. The controller compares
modbus RS 485, and here PLC is designed using So the output values with the required value and gives
Machine Basic software which then perk up the servo drive correction signals if any error presents.
and controls the motor as entered in HMI. Mechanical
equipment like single acting pneumatic cylinder switched on
to cut the paper to the required length.

Fig. 2: Schneider HMI(HMIGXU3512)

B. Programmable Logic Controller (PLC)
Programmable Logic Controller also called as
programmable controller is a digital computer used for Fig. 4: Servo Set (LXM23DU)
controlling of machinery on factory assembly line. PLC is
an industrial computer control system that continuously D. Mechanical Perception
looks after the condition of input devices and makes the As the machine used to cut the paper, importance is given to
decision based upon the custom program to control the the length drawn to cut. The paper is drawn with the help of
condition of output devices. motor shaft which is controlled by Programmable Logic
It was first developed in the automobile industry to Controller (PLC). TM200C40U used here. The features and
provide flexible, shock-resistance and easily programmable technologies used in this system makes highly flexible and
controllers to replace hard-wired relays and timers. Since versatile and also reduce cutter position changeover time to
then they have been widely used as highly-trusted very acceptable level.
automation controllers applicable for harsh environments. It Pneumatic cylinder is a mechanical actuator which
converts the values into pulses as per the program. PLC send utilizes compressed air to create force in a reciprocating
command to the servo driver to command AC servo to rotate linear motion. Double-Acting Cylinder (DAC) utilizes the
to the prescribed speed and number of rotations. pressure imparted by compressed air to create a driving
force in both extend and retract strokes. This has two ports
to allow air in and out. One for out stroke and one for in
stroke. Toward one side of the piston cutter is placed, 5/2
solenoid activated DCV is used, once the required length of
the paper is drawn PLC will incite the solenoid to cutter
down to cut the paper at the correct position.

Fig. 3: Schneider PLC (TM200C40U)

The PLC used here is TM200C40U where M200 is
a model name, C40 means it has 24 inputs and 16 outputs, Fig. 5: Pneumatic Cylinder

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 Development of PLC based Automatic Prototype Cutting Machine
(IJSRD/Vol. 5/Issue 06/2017/019)

IV. SOFTWARE USED b) Below (Fig.9) shows the menu of the cutting
machine which run in two mode i.e auto mode and manual
A. Vijeo Designer Basic Designing
mode
The main window of Vijeo Designer Basics is as shown in
(Fig. 6). And it is followed by the procedure to use the
software to design the HMI.

Fig. 9: Menu of the cutting machine which run in two mode

c) Below (Fig 10) shows auto mode panel where
required length, speed and numbers of count required.
Fig. 6: Vijeo Designer Basic Main Window
Steps to Run the Software
1) Create new project – in iq manager create new driver -
select modbus equipment – com

Fig. 10: Auto Mode Panel

d) Below (Fig.11) shows the manual mode panel
where the cutter position, servo motor rotation is manually
Fig. 7: Create New Project Window done it involves the push button operation.
2) The required panels for the model is created as shown in
the below Figures
a) Figure shows the welcome window

Fig. 11: Manual Mode Panel

Fig. 8: Welcoming window

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 Development of PLC based Automatic Prototype Cutting Machine
(IJSRD/Vol. 5/Issue 06/2017/019)

e) Below figure shows the settings panel where this

step is done first before starting the operation and here can
adjust the required pulses per minute can be added

Fig. 14: Electric Panel

For changing in parameter like varying length
several trails are carried out from 10mm to 100mm for
number of counts done on this machine. By entering the
required length through HMI, the output signals from HMI
is input to the PLC where length is converted to pulses. HMI
is used to interface and PLC is used as controller, and servo
Fig. 12: Settings Panel motor generate pulses.
B. PLC Programming
VI. CONCLUSION
The main window is as in the figure 13. Here before
As coated in literature survey cutting is a continuous mass
programming, configuration of PLC model is selected, type
production technique, the cutting process contributes about
of pulse generators
80% in manufacturing of product in manufacturing sectors
like paper industry. Hence the work place a major part in
this field. Here, to cut a paper of varying parameter like
length and different number of counts a system is developed
and analysed. This analysis is achieved by using human-
machine interface (HMI), Programmable Logic Controller
(PLC), and servo motor and single acting pneumatic is used
since it uses compressed air and main advantage is there will
be no oil leakage, which reduces cost and time lost in tool
change. The system developed can cut the papers for given
length by converting it to pulses in mimum time and given
number of counts. That results in lead time reduction and
reduced manpower which intern increases throughput.
Fig. 13: Main Window of SoMachine Basics.
VII. SCOPE FOR FUTURE WORK
V. RESULTS This work can be established in all the manufacturing
sectors for reduced inventory, and for the better performance
The method of extraction of result and analysis of data is with increased accuracy. By using Programmable Logic
done here. The parameters considered for this purpose are as Controller (PLC) any process can be automated by writing
followed: the program for the process. Any raw materials like rubber,
 Cut off length lather or timbers can cut within a minimum time, with more
 Speed of rotation efficiency.
 Pulses per rotation
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