Automation of Packaging and Material Handling Using Programmable Logic Controller

This paper presents an automation of packaging and material handling using a programmable logic controller. The idea is to automate the process of placing the materials inside a box, detecting good and bad items in terms of weight, and sealing using a packaging tape. The purpose of the study is to replace the manual system being used in the industry, compare the time, and manpower requirement for both the existing system with the proposed automated system. The Mitsubishi FX series programmable logic controller is used to mechanize the system. Sensors such as proximity and load sensor are used to provide the input to the system. The motors, pneumatics, and also the solenoids serve as the output. The researchers used a ladder diagram as a software that will control then the whole system between its input and output components. An experimental prototype is produced to fully automate the system. The experimentation is done through different trials and the rate of travel time is measured thru averaging. It is found out that the system decreases time and manpower requirements for every station as compared with traditional manual system. A reduction of 50% to 75% was observed in terms of time allotment for filling, weighing, and sealing stations. About 90% of full automation without human is specified also in the system. The paper ends with the recommendation of integrating the experimental prototype with the human machine interface or HMI, and feedback mechanisms for the rejected items using artificial intelligence techniques and methods. Keywords?Packaging, Programmable Logic Controller, Material Handling, Load, Sensor