PLC-HMI BASED AUTOMATIC SCREEN PRINTING SYSTEM

Transcription

1 International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 10, October 2017, pp , Article ID: IJMET_08_10_013 Available online at ISSN Print: and ISSN Online: IAEME Publication Scopus Indexed PLC-HMI BASED AUTOMATIC SCREEN PRINTING SYSTEM Dr. A. Selwin Mich Priyadharson and Prabhu Kumar Surarapu ECE Dept, Vel Tech University, Chennai, India ABSTRACT The proposed work is to develop and design a fully automated Screen printing system which will be controlled and operated using PLC-HMI. The current industrial printing system involves the usage of microprocessors and relays to control and in addition includes lot of manual interference. The coding process in microprocessors are low efficient and not suitable for complicated and high end applications. In this work a mechanical setup is made to execute the printing, a printing mechanism that suits the setup and the code is developed based on PLC- HMI. The mechanical setup consists of the conveyor mechanism holding the paper on side, lifting arrangement, wiping setup, cutter and sensors. For controlling the printing operation and Automating the screen printing set up, power panel 4PP045 and PLC is utilized. The setup encompass control system (inbuilt processorsupporting both analog and digital inputs), motion system (gear assembly, servo motors), IO modules (12 input and output ports with temperature sensors port) & visualization (HMI). In this work PLC is programmed using ladder diagram and advanced HMI is designed with hotspots, buttons and active points to control the printing operations. In this proposed PLC - HMI based Automatic screen printing system; printing will be in a continuous fashion without manual intervention. The synchronism between the lifting and wiping processes will carry out by PLC. Consequently a very reliable and highly accurate printing will be attained. Key words: PLC-HMI, Screen Printing, Servo Motor, ACOPOS (Automatic COntrol of POSition). Cite this Article: Dr. A. Selwin Mich Priyadharson and Prabhu Kumar Surarapu, PLC-HMI Based Automatic Screen Printing System, International Journal of Mechanical Engineering and Technology 8(10), 2017, pp INTRODUCTION Screen Printing is one of the oldest and the most versatile printing technique. Screen printing is used in many different industries such as clothing, decals, balloons, medical devices, printed electronics (including circuit board printing), product labels, signs and displays, snowboard graphics, textile fabric, thick film technology editor@iaeme.com

2 Dr. A. Selwin Mich Priyadharson and Prabhu Kumar Surarapu Yun Long Yuan et al [1] used PLC as the control core, developed the automatic PLC control system and applied the reasonable programming skills in screen printing equipment which greatly improved the production efficiency. Ramesh Kumar et al [2] surveyed on various sheet-fed offset automation techniques existing today and their futuristic implications. Pinki et al [3] studied the choice of people in print quality produced by different printing. Prepared test chart that contains the different types of images and then printed through offset, inkjet, screen and digital printing processes. Conducted survey on hundred people to find out the printing process which gives best impact of print quality in human mind. Jacek Hamerlinski et al [4] conducted study desired to increase the accuracy of estimating paper quantity requirements for printing.gao Zhenqing et al [5] proposed automatic regulating technology in offset printing machine. Designed hardware system by the embedded ARM controller as the core of the automatic control system. Zhang Huaizhi et al [6] solved the key technical problems such as feeding mechanism, ammunition holding mechanism, screen printing mechanism, synchronizing mechanism and so on in the process of system; designed the pneumatic system and PLC control system. Jianbiao Panet al [7] focused on investigating the effect of manufacturing process parameters on fine line printing through the use of statistical design of experiments. The process parameters included are print speed, squeegee hardness, squeegee pressure, and snap-off distance. To overcome the difficulties such as inherent time delay, and nonlinearity in printing process in the existing printing schemes and thereby to enrich the performance of the screen printing machine, the PLC-HMI based automatic screen printing system is developed. This paper is designed as follows: Section 2 deals with the Programmable Logic Controller. Section 3 deals with PLC-HMI connection set up. Section 4 describes the screen printing machine mechanical set up. Section 5 describes the printing mechanism - process. Section 6 deals with Visualization. Section 7 gives the designed HMI and its operation for screen printing machine. Section 8 describes the PLC-HMI based automatic screen printing machine print.and Section 9 deals with conclusion. 2. PROGRAMMABLE LOGIC CONTROLLER (PLC): PLC, digitally operating electronic apparatus which uses a programmable memory for the internal storage of instructions by implementing specific functions such as logic sequencing, timing, counting and arithmetic through digital or analog input/output modules is employed for controlling this Automatic Screen Printing system. Hardware components of a PLC system are shown in Figure.1. It has Input/output sections, Power supply unit, Central Processing Unit (CPU), Memory section, Programming device and System buses. Figure 1 PLC system for automatic screen printing machine editor@iaeme.com

3 3. PLC - HMI CONNECTION SETUP PLC-HMI Based Automatic Screen Printing System Figure 2 PLC- HMI connection setup The PLC connection set up is shown in Fig.2. Its material and description is mentioned in Table. 1. Material Power Panel Motion Control (ACOPOS) I/O Systems Servo Motors Table 1 PLC Connection Setup Material -Description Description 4PP V1010 with Motor Holding Brake and Temperature Sensors. X20DI9371, X20DO9322, X20AI2622, X , X20AT6402 8MSA2 RO-67 MODEL CLASS F 0.11to21W Power oil seal advanced braking system. ACOPOS (Automatic COntrol of POSition) is to control the position of motors and to control the various characteristics such as temperature of the motor. High precision servo motors are employed for position control with very high speed of 6000 m/min. It has a very advanced cooling and braking system and thus enabling accurate control of position. 4. SCREEN PRINTING MACHINE MECHANICAL SETUP Figure 3 Screen printing machine mechanical set up editor@iaeme.com

4 Dr. A. Selwin Mich Priyadharson and Prabhu Kumar Surarapu Screen printing is a stencil process in which the printing involves both closed and open non image areas. Ink is forced through a screen by resilient squeegee. In the proposed PLC- HMI based screen printing machine, a woven mesh is used to support an ink stocking stencil. A screen is made of a piece of porous, finely woven fabric called mesh stretched over a frame of aluminum. Areas of the screen are blocked off with a non-permeable material to form a stencil which is negative of the image to be printed that is the open spaces where the ink will appear. The attached stencil forms open areas of mesh that transfer ink which is pressed through the mesh as a sharp-edged image onto a substrate. A squeegee is moved across the screen stencil, forcing or pumping ink past the threads of the woven mesh in the open areas. The screen is placed on top of a substrate such as paper or fabric. Ink is placed on top of the screen and a fill bar (flood bar) is utilized to fill the mesh openings with ink. 5. PRINTING MECHANISM - PROCESS: The original image is created using the computer in black color. Then the black image is utilized to produce the negative copy on a transparent overlay such as acetate or tracing paper. The image may be drawn or painted directly on the overlay, photocopied or printed with an inkjet or laser printer as long as the areas to be inked are opaque. The positive copy thus prepared is placed along with the photosensitive paper in the exposing glass. The exposing glass is exposed to sunlight or to Ultra Violet (UV) for 5 minutes. The UV light passes through the clear areas and create a polymerization (hardening) of emulsion when exposed to the hydrogen peroxide solution (1:3 solution) taken in the plastic tray. It is soaked in the solution for 60 seconds. The screen is washed off thoroughly. The areas of emission that were not exposed to light dissolve and wash away leaving a negative stencil of the image. The negative copy thus produced is placed on the wooden frame. Adequate amount of ink or dye is added and the roller is moved over the screen to form the image on the paper. 6. VISUALIZATION Visualization is made by designing Human Machine Interface (HMI) which is used to operate the PLC as user friendly. A variety of devices have been exploited for interfacing screen printing machines to provide easy control of operations. The most modern technique is the use of touch screen in HMI to give the inputs is exploited in this proposed screen printing machine. Touch screen is more superior to other interfacing devices since it is very easier to give inputs to the PLC. The operations can also be monitored using the HMI screen. Whenever any operation is being performed it is displayed on the HMI screen and thus enables the user to keep track of what is happening. The Automation studio Version 2.5, PLC proprietary software, provides a user friendly interface for creating and calibrating the touch screen. It has various dynamic features such as profiler, logger, program watch that facilitate the user to carry on the programming task and assists in easy correction of the mistakes made. 7. DESIGNED HMI SCREEN AND ITS OPERATION FOR SCREEN PRINTING MACHINE Fig. 4 represents HMI screen Overview. Then Login HMI screen will appear as in Fig. 5. Password will be entered for getting login. Automatic or Manual mode will be enabled by touch in touch screen which it is shown in Fig editor@iaeme.com

5 PLC-HMI Based Automatic Screen Printing System Figure 4 HMI screen overview Figure 5 HMI screen - login Figure 6 HMI screen automatic/manual buttons Figure 7 HMI screen manual mode Figure 8 HMI screen entering number of prints Figure 9 PLC- HMI screen Fig.7. represents the Manual Mode buttons Induction Motor, Wiper Motor and Servo Motor to move Forward and Backward manually by touching those appropriate buttons. Fig. 8. PLC-HMI Screen Hardware Set up editor@iaeme.com

6 Dr. A. Selwin Mich Priyadharson and Prabhu Kumar Surarapu Figure 10 PLC-HMI interfaced with screen printing machine 8. PLC HMI BASED AUTOMATIC SCREEN PRINTING MACHINE PRINT Figure 11 Automatic screen printing machine printed copy Fig.11. shows the automatic Screen printing machine, printed copy. The proposed PLC HMI based screen printing machine performed full automation with high speed in printing and precise in print copy without manpower. 9. CONCLUSIONS This work is carried out to design an Automated Screen Printing Machine using PLC-HMI. The existing system for screen printing is carried out manually by piece by piece method involving abundance of labor, consuming time and resulting in wastage of human and material power. PLC-HMI based Automatic Screen Printing Machine has executed printing at high speed and greater accuracy with reduction of manpower. The printing operation is simplified and the performance of the screen printing machine was improved using PLC- HMI. Also it has enriched the stability and reliability of the screen printing machine. In the existing printing system, approximately 10 pages can be printed per minute. Moreover the output is limited by the efficiency and ability of the operator. Whereas in the proposed PLC-HMI based Automatic Screen Printing Machine, the printing will be carried out at much greater speed since very high speed servo motors controlled by the ACOPOS (Automatic COntrol of POSition) are used for carrying out the printing process. Printing accuracy and precision in the order of micrometer has been achieved using the proposed PLC- HMI based screen printing system

7 REFERENCES PLC-HMI Based Automatic Screen Printing System [1] Yun Long Yuan, Hong Cheng, Screen Printing Equipment Control System Design Based on PLC Applied Mechanics and Materials, Trans Tech Publications, Switzerland, Vol 415, pp , [2] Ramesh Kumar, Bijender & Mr. Sandeep Boora, A Survey of Automation Techniques coming forth in Sheet-fed Offset Printing Organizations International Journal of Engineering Sciences &Research Technology, Vol 6, Issue 6, June, [3] Ms. Pinki, Comparative Study of Print Quality of Different Printing Processes from People s View International Journal of Engineering Sciences & Research Technology, Vol 6, Issue 7, July, [4] Jacek Hamerlinski, YuriyPyr,yev, A method of minimizing paper requirements for offset printing, Bio Resources, Vol 9, Issue 3, pg [5] GAO Zhenqing, SUN Hanxu, Research on Gap Adjustment for Offset Printing Machine Based on ARM Applied Mechanics and Materials Vol 364, pp , [6] Zhang Huaizhi,Fu Song, Cao Hongan, XieJunlei, XieQuanmin, Development of Screen printing automatic equipment for Ammunition marking Sixth International Conference on Intelligent Systems Design and Engineering Applications, IEEE Computer Society, [7] Jianbiao Pan, Gregory Tonkay and Alejandro Quintero, Screen printing process design of experiments for fine line printing of thick film ceramic substrates Journal of Electronics Manufacturing, Vol. 9, No. 3, pg , Sept [8] Guosheng Shi, Electrical control and PLC Technology, third ed., Chemical Industry Press, Beijing, [9] Jun Wu, The Principle and Technology of Screen Printing, China Light Industry Press, Beijing, [10] Kipphan, H. (Ed.). (2001). Handbook of print media, technologies and production methods (1st Ed.).Berlin: Springer. [11] Selwin Mich Priyadharson, A., Vinson Joshua, S., and Thilip Kumar, C., PLC - HMI and Ethernet based monitoring and control of MIMO system in a petrochemical industry Indian Journal of Science and Technology, Volume 8, Issue 27, [12] Dr. A. Selwin Mich Priyadharson, Vinson Joshua. S and Senthil Kumaran. B PLC - HMI Based Pipeline Leakage Detection System in Petroleum Transfer Lines Global Journal of Pure and Applied Mathematics. Volume 11, Number 3, pp , [13] A. Selwin Mich Priyadharson, Ramesh Kumar and M. S. Saravanan, Neural Cascaded with Fuzzy Scheme for Control of a Hydroelectric Power Plant American Journal of Applied Sciences, Science Publications, USA, [14] Dr. A. Selwin Mich Priyadharson, "GPS and PLC - HMI based Lavatory Flush Control in Indian Railway Compartments" International Journal of Electrical Engineering and Technology (IJEET), [15] A. Ramya And Sai Leela Vanapalli, 3d Printing Technologies In Various Applications. International Journal of Mechanical Engineering and Technology, 7(3), 2016, PP editor@iaeme.com