AC 2011-1607: CONVEYOR CONTROL SYSTEM PROJECT

David R. Loker, Pennsylvania State University, Erie

David R. Loker received the M.S.E.E. degree from Syracuse University in 1986. In 1984, he joined
General Electric (GE) Company, AESD, as a design engineer. In 1988, he joined the faculty at Penn State
Erie, The Behrend College. In 2007, he became the Chair of the Electrical and Computer Engineering
Technology Program. His research interests include wireless sensor networks, data acquisition systems,
and communications systems.

Robert Weissbach, Pennsylvania State University, Erie

Robert Weissbach is currently an associate professor of engineering and incoming director of the Ap-
plied Energy Research Center at Penn State Erie, The Behrend College. Prior to completing his doctoral
studies, he was employed by General Dynamics Electric Boat Division where he worked on the design
and construction of submarine turbine generator sets. From October 2007 through June 2008, he was a
visiting researcher at Aalborg University in Aalborg, Denmark. Dr. Weissbach is a Senior Member of
IEEE and is a registered engineer in Pennsylvania. His research interests are in renewable energy, energy
storage, power electronics and power systems.

Adam Henry, Penn State

Adam Henry is currently a senior at Penn State Erie, The Behrend College majoring in the Electrical and
Computer Engineering Technology program. His interests are computers and related technology. He also
enjoys designing and building electrical devices to use in his daily life.

Page 22.383.1

American
c Society for Engineering Education, 2011
 Conveyor Control System Project

Abstract

Part of the requirements in a junior-level measurements & instrumentation course (for an Electrical
and Computer Engineering Technology program) includes an end-of-semester design project. One
possible project is the design and implementation of a conveyor control system. For this project, the
conveyor simulator is pre-fabricated and equipped with a 24-volt DC motor mounted directly to a
plastic spindle for driving the conveyor belt, a freely rotating plastic spindle for the opposite side of
the conveyor belt, and two Plexiglas sides. Three IR reflective sensors (one in the middle and one at
each end) are used to detect the position of an object on the conveyor. The objective of the project
is for students to design the software (using LabVIEW) and hardware interfacing electronics for the
conveyor control system such that it mimics the operation of a conveyor with beginning, stamping,
and ending stations. Students are required to use a National Instruments data acquisition system
with analog I/O and digital I/O capability. This paper provides a detailed listing of the engineering
requirements for the system, the functional test procedure for verifying proper operation of the
system, and results. In addition, since this conveyor control system is also a lab project for a
sophomore-level PLC course, results are provided for the PLC-based control system along with an
assessment based on the comparison of the advantages and disadvantages for PC vs. PLC control.
Recommendations are included to help ensure student success on the project. The PC-based control
system project has been found to be an effective end-of-semester project for two reasons. First, it
integrates both hardware and software design while utilizing information covered from prerequisite
courses. Second, due to the slow time response characteristics of this system, PC-based control is
suitable for this application.

Introduction to the Measurements and Instrumentation Course

This is a required first semester junior-level course for Electrical and Computer Engineering
Technology students. Details about the course are available1. A primary objective of the course
includes using LabVIEW and data acquisition (DAQ) cards for the design of both measurement
systems and control systems2-3. Rather than requiring students to take a final exam, this course
requires an end-of-semester design project. One possible project is the design of an automated test
and measurement system1. An alternative option is for students to design a conveyor control
system, and students can choose the project that is most interesting. The purpose of this paper is to
describe the details about this conveyor control system project.

Conveyor Control System Project

Students are provided with a prebuilt conveyor simulator and a PC-based DAQ system containing
analog I/O and digital I/O capability. The objective is to design a control system for the conveyor in
order to meet a set of practical engineering requirements.

This project is appropriate for a measurements and instrumentation course since it requires both
hardware and software design for interfacing the conveyor to a PC-based DAQ system for a
Page 22.383.2

measurement and control application. Infrared proximity sensors are used for detecting the position
of an object on the conveyor. The time response characteristics for this system are sufficiently slow
such that control theory for dynamic control applications is not needed4.

Conveyor Simulator

The conveyor simulator uses a 24V dc motor that draws approximately 300mA, Plexiglas side
walls, sandpaper for the track, and three OR500-ND infrared proximity sensors5. A pre-made part
gets placed in front of the first infrared sensor which will start the dc motor. The part will continue
down the conveyor at an approximate speed of 1 inch/second until a second infrared sensor is
reached and the conveyor will stop. The part will be stamped by the user, and then the part will
continue down the conveyor until the third and final infrared sensor. Then the conveyor will stop
operation and wait for another part to be placed in front of the first sensor. A drawing of the
conveyor is shown below in Figure 1.

Figure 1. Conveyor Simulator.

Engineering Requirements for project

Special features:

• LabVIEW software development environment

• Pre-built conveyor simulator used for the control system
• Conveyor simulator interfaced to the NI USB-6008 DAQ card6
Page 22.383.3
User Interface Requirements:

• A Boolean control on the front panel to indicate that the conveyor is ready to be started
• A display on the front panel to indicate the state of the conveyor
• A display on the front panel to indicate if a part is on the conveyor
• A button (or toggle switch) on the front panel to simulate the stamping action

Functional Requirements:

• If no part is on the conveyor it will not operate

• When a part is placed in front of the first sensor and the ready button is pressed, the part
automatically moves to the second sensor
• When the part reaches the second sensor, the conveyor stops to allow the part to be
stamped
• The part stamp can’t function unless the conveyor has stopped and the part is in front of
the second sensor
• After the part is stamped, it will automatically continue to the end
• After the part reaches the end, the conveyor stops and the system waits for a new part to
be placed in front of the first sensor
• The conveyor motor can only be started 3 times within one minute to avoid overheating

Operating Sequence:

• Once program is started it waits for user to be ready

• Once the ready button is pressed, the program checks for a part on the conveyor in front of
the first sensor
• If no part is found in front of the first sensor, the program displays the error and re-loops
back to wait for the user
• If a part is found, the conveyor starts and the part begins moving down the conveyor
• The program displays to the user that the conveyor is moving
• When the part reaches the second sensor, the conveyor stops, the part gets stamped, and the
part continues to the end of the conveyor
• The program waits until the part is removed from the conveyor
• If the stop button has not been pressed, the program re-loops

Documentation:

• VI online description
• Title information is presented on front panel
• Appropriate comments are provided on block diagram

Deliverables:

• Soft copy of the lab report

Page 22.383.4

• Soft copies of VI and all SubVIs

Hardware Design for Project

The schematic for the hardware design is shown in Figure 2. To interface with the 24V DC
motor, a motor driver circuit was designed that consists of a TIP31C transistor and a TIP32C
transistor configured as switches. When the DAQ card outputs +5 V DC, both transistors are
switched on. This will cause approximately 24V to be applied across the motor to turn it on.
When the DAQ card outputs 0V DC, both transistors are switched off, which cause the motor to
turn off.

To obtain a usable signal from the IR sensors, an LED driver circuit was designed that consists
of a 3k ohm potentiometer to adjust the current passing through it in order to change the range of
the detector. The detector circuit consists of a 1M ohm current limiting resistor, a 6k ohm base
resistor connected to a 2n3904 transistor, and a 1k ohm base resistor connected to a 2n3906
transistor. When the detector sees sufficient infrared light reflecting off the part, both transistors
are switched on. With the voltage divider from R2 and R3, this will cause 10V to be applied to
the analog input channel of the DAQ card. When the detector does not see sufficient reflective
infrared light, both transistors are switched off, which cause the analog input channel voltage to
be 0V.

Page 22.383.5

Figure 2. Schematic for PC Hardware Design.

Software Design for Project

A flowchart for the software design is shown in Figure 3. The flow of the program is as follows:
1. User presses the ready button.
2. The program then waits for a part to be placed in front of sensor 1.
3. When a part is placed in front of sensor 1, the program checks the number of times the
conveyor motor has been started within 1 minute. If the conveyor motor has been started
3 times within 1 minute, the program will not allow the conveyor to start again until the 1
minute timer has timed out.
4. If the conveyor has not been started 3 times within 1 minute, the conveyor starts and the
part moves toward sensor 2.
5. Once the part reaches sensor 2, the conveyor is stopped and the program waits for the
stamp button to be pressed.
6. Once the stamp button is pressed, the stamp indicator is illuminated.
7. If the conveyor has not been started 3 times within 1 minute, the conveyor starts and the
part moves toward sensor 3.
8. When the part reaches sensor 3, the program stops the conveyor operation, unlatches the
ready button, and turns off stamp indicator.
9. If the stop button is not pressed, the program re-loops.

Page 22.383.6
 Figure 3. Flowchart for PC Software Design.

For the software design, a state machine was used. Table 1 lists each state of the state machine,
along with the function of each state. Figure 4 shows the screen shot of a portion of the block
diagram of the LabVIEW program. Page 22.383.7
 Table 1. PC State Machine Design.
State Function
Init All variables are initialized to default, and it transfers to the “No
Event” state.
No Event Monitors all inputs (Sensor 1, Sensor 2, Sensor 3, Ready Button, and
Stamp Button). When a state change occurs, it transfers to the
appropriate state.
Run Conveyor Starts the conveyor motor and transfers to the “No Event” state.
Sensor 2 Reached Part has reached the middle sensor and the conveyor is stopped. It
transfers to the “No Event” state and waits for the stamp button to be
pressed.
Stamped The stamp button has been pressed, and then the conveyor motor is
started.
Sensor 3 Reached Part has reached the last sensor and the conveyor is stopped. It
transfers to the “No Event” state and waits for the stamp button to be
pressed.

Figure 4. Screen shot of LabVIEW block diagram.

The screen shot of the front panel of the LabVIEW program is shown in Figure 5. It uses 5
Boolean indicators, 3 Boolean controls, 1 text indicator, and 2 channel inputs. The Ring indicator
displays the current state of the state machine for debugging purposes. The sensor 1, 2, and 3
Boolean indicators show when a part is in front of each sensor. The conveyor state indicator
Page 22.383.8

displays the following:

 • When the conveyor is running, the indicator is green and displays the message
“RUNNING”.
• When the conveyor is not running, the indicator is red and displays “NOT RUNNING”.

The indicator directly above the conveyor state indicator is hidden unless the part reaches the
third sensor. When it reaches this sensor, it becomes visible and blinks between the colors yellow
and red and displays “PLEASE REMOVE PART”. The button that displays “READY” is used
for the user to tell the program when they are ready to start operation. The “Stamp it” control is
used for the user to “Stamp” the part. This control is disabled unless the part is in front of sensor
2 and the conveyor is stopped. The “STOP” button is used to end the program. The “Input
Channels” control is used to specify the input channels for the three sensors. The “Output
Channel” control is used to select the channel that will interface to the motor control circuit
which runs the conveyor.

Figure 5. Screen shot of front panel of LabVIEW program.

Functional Tests for Project

Several tests were performed to demonstrate successful operation of the elevator control system, as
shown below in Table 2. Each test is numbered with a description and a pass/fail indication.

Page 22.383.9
 Table 2. Functional test procedure.
Test
Function Description Pass/Fail
number
Conveyor button does not operate unless the ready
1 Ready Button
button is latched.
Conveyor and part on the conveyor will start
Starting the
2 moving only if the ready button is pressed and the
conveyor
part is in front of sensor 1.
Part reaches
3 Conveyor motor stops when part reaches sensor 2.
sensor 2
Part will not continue until stamp button is pressed.
4 Stamp button Once stamp button is pressed, the conveyor starts
and part continues down conveyor.
Sensor 3 When sensor 3 is reached, conveyor stops operating
5
reached and user is notified.
Remove part
The process repeats when part is removed from
6 and place at
sensor 3 and replaced at sensor 1.
beginning
Ready button is
7 unlatched during Conveyor stops immediately and notifies user.
operation
The conveyor motor can only be started three times
8 Overheating
within 1 minute to avoid overheating.

PLC Implementation

The PLC implementation was performed on an Allen-Bradley controller7. The parts list is shown in
Table 3 and the schematic is shown in Figure 6. Some additional functional requirements were
specified for the PLC design.
• If a 10-second timer times out before the part reaches the second sensor, the conveyor is
stopped and an alarm is lit. The program will only continue after an alarm acknowledge
button is pressed.
• A 5-second timer is used to simulate that a part has been stamped.

These additional requirements were specified by the instructor for the sophomore-level PLC course.
Page 22.383.10
 Table 3. Parts List for PLC Implementation
Controller 1769-L32E
Power Supply 1769-PA2
Digital Input 1769-IQ16
Digital Output 1769-OW16
Ethernet Switch ---
2 NC Push Buttons Run, Alarm Acknowledge
1 DC Motor Motor
2 Lights Motor Running, Alarm
3 IR Proximity Sensors OR500-ND

Figure 6. PLC schematic.

Table 4 lists each rung of the ladder diagram along with its function. Figure 7 shows the screen
shot of the ladder diagram.
Page 22.383.11
 Table 4. Ladder Diagram Design.
Rung Function
0 If ready button becomes unlatched, move the value 0 to the motor_started tag and
unlatch motor output and stop conveyor.
1 If ready button is true, 10 second timer has not timed out, and motor output (Start)
is true, then move the value 1 to the Motor_Minute tag, increment the number of
times the motor has been started by 1, and illuminate the
Motor_Running_Indicator.
2 If the motor has been started 3 times within one minute, wait for the motor running
indicator to become false. Once it becomes false, move the value 4 to the number
of times the motor has been started within 1 minute. This stops the conveyor from
being started a 4th time within 1 minute.
3 If the motor has been started 3 times within a minute, keep the motor output false.
4 Once the 1 minute timer has timed out, reset the number of times the motor has
been started and the 1 minute timer.
5 If ready switch is true, the motor has not been started more than 3 times within 1
minute, and the part is in front of sensor 1, jump to the start motor subroutine.
6 If the ready switch is true and the motor has been started, then start the 10 second
timer.
7 If the ready switch is true and the motor has been started, start the 1 minute timer.
8 If the 10 second timer has not timed out and the part reaches sensor 2, jump to the
Sensor_2_Reached subroutine.
9 If the 10 second timer times out before the part reaches sensor 2, stop the conveyor
and illuminate the alarm. Once the alarm acknowledge button has been pressed,
reset the 10 second timer.
10 If sensor 3 is reached while the conveyor is running, jump to the
Sensor_3_Reached subroutine.

Page 22.383.12
 Page 22.383.13

Figure 7. Screen shot of ladder diagram.

Project Assessment

Table 5 provides results from a student questionnaire. Table 6 provides a student comparison of the
advantages and disadvantages for the PC and PLC systems. Overall, the student response to this
project indicates that it was a great learning experience. However, more data will need to be
collected for statistically relevant results.

Table 5. Student Questionnaire Results.

Questions PC System PLC System
Approximate time in hours to
5 5
complete hardware design
Approximate time in hours to
5 6
complete software design
Overall level of difficulty Low Low
Areas of difficulty Hardware, State Machine Timers, Counter
Suggestions for improvement Review of hardware Review of timers and
to help ensure student success interfacing electronics counters
Suggestions for number of
2 2
students on this project
Suggestions for number of
2 2
weeks to complete project

Table 6. Student Comparison of PC and PLC Systems.

System Advantages Disadvantages
PC • Since the PC system used the USB • The PC system is not as robust as the
DAQ, it was much more portable PLC system and requires a working PC
than the PLC system. running specific software to interface
• All of the controls and indicators for with the specific hardware.
the PC system were contained on the • The system also is not a real-time control
front panel. system. This was not a problem due to
the slow time response characteristics for
this system.
PLC • The PLC system did not need any • The PLC system was too large to be
separate circuitry to run the portable.
conveyor’s DC motor. • It had to be tested in the lab.
• The inputs and outputs are very easily • It required having separate pushbuttons
addressable and require no extra and indicators as well as the controller
programming to separate the and input cards.
incoming data. • It required more hardware wiring.
• The system does not need a PC • The Allen Bradley controller and
connected to it once it is software are much more expensive than
programmed. the PC hardware and software.
Page 22.383.14
Conclusions

In this paper, results are shown for both a PC-based and PLC-based conveyor control system.
Due to the slow time response characteristics of this system, the PC-based control system has
been as effective as the PLC system. Both types of systems integrate hardware and software
designs. The tradeoffs to consider are real-time control, portability, robustness, and cost.

Recommendations

For the PC system, it is recommended that transistor theory be reviewed prior to the start of the
project. Also, 2-3 hours of lecture should be allotted for introducing state machines. This should
also include an example of the design of a state machine.

For the PLC system, it is recommended to review how timers and counters function. Students
will also need to be familiar with how NO and NC contacts work both in hardware and software.

Acknowledgment

I would like to thank Roger Kuntz, the instructor for the sophomore-level PLC course, for
providing information regarding the engineering requirements for the PLC implementation of this
project.

Bibliography

1. Loker, D., “Elevator Control System Project,” Proceedings of the Annual Meeting, American Society for
Engineering Education, 847_ELEVATOR_CONTROL_SYSTEM_PROJECT.pdf on CD-ROM, 10 pp., Louisville,
KY, 2010.
2. Bishop, Robert H., Learning with LabVIEW 2009, Pearson Education, 2010.
3. Travis, Jeffrey and Jim Kring, LabVIEW for Everyone, 3rd Edition, Pearson Education, 2007.
4. Nise, Norman S., Control Systems Engineering, 5th Edition, Wiley, 2007.
5. Web Site http://www.digikey.com.
6. Web Site http://www.ni.com.
7. Web Site http://www.ab.com.

Page 22.383.15