International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1910 Multilevel Object Sorting System using PLC Controller Rohit R. Yadav 1 , Shubham S. More 2 , Onkar N. Mutekar 3 , Aditya L. Mogal 4 , Rayappa S. Mahale 5 1,2,3,4 UG Students, Department of Mechanical Engineering, D Y Patil School of Engineering Academy, Pune, Maharashtra 5 Assistant Professor, Department of Mechanical Engineering, D. Y. Patil School of Engineering Academy, Pune, Maharashtra, India. ---------------------------------------------------------------------***---------------------------------------------------------------------- Abstract:- In many industrial applications there is need of sorting. Sorting can be done by using many ways like sorting of object according to their dimensions (height, length etc.), according to their colours, according to their weight, using machine vision (image processing), according to the material of an object etc. For example in Thermal Power Station electromagnetic sorting technique is used to sort ferromagnetic materials from coal. In this project, the development of a LCA (Low Cost Automation) system to sort objects according to their height has been designed. This LCA system is controlled by Programmable Logic Controller (PLC). This project consists of two parts, first consisting of software which contains ladder logic programming which is used to program PLC that controls the whole process of the project step by step according to input data sequence. Second is the hardware part which consists of conveyors used to transport the objects, sensors used to sense the height (i.e. laser sensors) of the objects, electronic system used to sort the objects and motors to drive the conveyors. Keywords: Automation, Programmable Logic Controller (PLC), Low Cost Automation, Sorting, Manufacturing. 1. INTRODUCTION Our aim in this project is to create the electronic material handling system which can be used to reduce the efforts of workers as well as to reduce the time spent in inspection of the components, during their manufacturing. It also reduces the efforts in transferring the components manufactured to another workstation. The most apparent reasons that are associated in installing of automatic system in industry are, i. Saving Man Power. ii. Improved Quality and Efficiency. iii. Increase consistency and Flexibility. An automatic sorting machine has main task of sorting components according to the sizes. This also consists of conveyor belt, which reduces the efforts of material handling. Also both processes take place simultaneously like material handling and inspection. 2. COMPONENTS: 2.1 PLC A programmable logic controller (PLC) or programmable controller is an industrial digital computer which has been ruggedized and adapted for the control of manufacturing processes, such as assembly lines, or robotic devices, or any activity that requires high reliability control and ease of programming and process fault diagnosis. PLC programs are typically written in a special application on a personal computer, and then downloaded by a direct- connection cable or over a network to the PLC. The program is stored in the PLC either in battery-backed-up RAM or some other non-volatile flash memory. Often, a single PLC can be programmed to replace thousands of relays. Currently five programming languages for programmable control systems: function block diagram (FBD), ladder diagram (LD), structured text (ST; similar to the Pascal programming language), instruction list (IL; similar to assembly language), and sequential function chart (SFC).These techniques emphasize logical organization of operations.[1] We used function block diagram (FBD) programming language for our PLC programming. 2.1.1 PLC specifications: PLC CPU-Schneider SR2 B121BD/ Zelio PLC Software- Somachine Basic 3.1/Zelio Soft Fig -1: PLC CPU