1. Your employer, Industrial Controls Inc. has been awarded a contract as a system integrator to design and install a gasket sorting process on an automated conveyor line. Your team of two engineers from the Controls Engineer group has been assigned to this project. The deliverables for your team are:

a. Vision job programmed in Cognex In-Sight Explorer which can 100% differentiate between good and bad gaskets.

b. Complete Cell PLC program with internal documentation.

c. Bill of materials for entire control system including electrical cabinet, PLC, disconnect, sensors and cables, safety devices, relays, etc.

d. Factory floor layout drawing.

e. Electrical cabinet layout drawing.

f. PLC and IO power distribution drawing.

g. Bill of materials for pneumatics and reject bin with a capacity of 100 gaskets.

2. The cell sequence is as follows:

a. Gaskets are conveyed to the infeed of the inspection cell at intervals of approximately 8 seconds with a speed of appromixately 0.75ft/s.

b. The gaskets are detected by the system with a sensor, triggering a vision inspection.

c. The vision system grades the gasket for the following features:

i. All three bolt holes must not have a blockage.

ii. The lower edge of the gasket must be oriented correctly within +/-30 degrees of parallelism to the conveyor.

iii. There must be no damage to the gasket in the locations shown in the Bad images.

iv. The lower and left edges of the gasket outline must be complete with no significant cutouts.

d. If the inspection fails, the system will use a pneumatic cylinder to push the gasket off the conveyor and into a reject bin.

e. The pneumatic cylinder needs extend and retract proximity sensors.

f. The reject bin must detect the rejected gasket with a through-beam sensor. If a gasket is not detected at the reject bin, the conveyor must stop.

g. If the reject bin is full, the cell is to turn on a klaxon horn and amber flashing light to alert the operator.

h. The cell is to use a combination of fencing and area scanners/light curtains to protect operators and maintenance from the hazards presented by the air cylinder, while still allowing access to empty the reject bin and for maintenance purposes.

i. If the cell safety circuit is broken, the cell PLC is to shut off safety relays which are part of the conveyor E-stop loop.

3 The customer has the following preferences for equipment vendors:

a. Electrical cabinets: Hoffman

b. Main disconnect: Allen-Bradley

c. Circuit breakers and fuse holders: ABB

d. Fuses: Bussman

e. Terminal blocks: Phoenix Contact

f. PLC: Allen-Bradley or AutomationDirect modular type

g. Vision System: Cognex 7000 series

h. Sensors: Banner or Keyence

i. Cordsets: Turck or sensor manufacturer

j. Operator Controls: Allen-Bradley 800T series

k. Wire tray: Panduit

l. Pneumatics: Festo

m. Network switches: Cisco

n. Klaxon: Edwards Signaling

o. Safety Devices: SICK

p. Power Supplies: SOLA

q. HMI: Allen-Bradley or AutomationDirect. At least 5 in size.

r. Vision system mounting: Swivellink AFSB Imperial series

s. All other hardware: Allied Electronics or McMaster-Carr

Additional notes and requirements:

The existing Flex-Link conveyor is an off white color, the gaskets are a dark grey color and 3mm thick.

The conveyor is approximately 12 inches wide.

The gaskets are approximately 9in x 6.5in.

Electrical drawing symbols will conform to NEMA ICS 19-2002.

Control devices will be powered by 24VDC.

Conveyor is 42 inches from floor surface.

Electrical panels should be floor mounted within the envelope given.

The Conveyor PLC requires a NC relay interface for:

a. Single input to stop the conveyor drive when necessary.

b. Dual inputs to E-stop the conveyor system if the cell E-stop button is pressed.

Extra Credit (10%): Create the PLC card drawings necessary for all IO used in this project. Submit on Canvas as a separate drawing file.

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