Automated_Assembly_Line_Simulation_16_9.pptx

Automated assembly line simuation

1. Project-Based Module: Automated Assembly Line Simulation An in-depth guide to designing and simulating an automated assembly line

2. Objective - Design and simulate an automated assembly line using Raspberry Pi, Arduino, and various sensors/actuators. - Understand the integration of different components in an industrial automation system. - Implement a basic control system to manage the assembly line process.

3. Background An automated assembly line is a manufacturing process where products move through various stages of production with minimal human intervention. Sensors and actuators play a crucial role in ensuring the process runs smoothly and efficiently.

4. Materials Needed - Raspberry Pi with OpenPLC installed - Arduino Uno - Conveyor belts (miniature models) - Proximity sensors, light sensors, and motor drivers - Actuators (e.g., motors for conveyor belts) - MQTT broker and client setup - Grafana for monitoring - Jumper wires, breadboards, and other prototyping tools

5. Procedure 1. **Setup and Configuration:** - **Raspberry Pi Setup:** - Ensure the Raspberry Pi is connected to your network. - Install and configure OpenPLC. - **Arduino Setup:** - Connect sensors and actuators to the Arduino. - Write Arduino code to read sensor data and control actuators. 2. **Designing the Assembly Line:** - **Conveyor Belt System:** - Set up miniature conveyor belts. - Connect motors to control the movement of conveyor belts. - **Sensor Placement:** - Place proximity sensors at critical points to detect product presence. - Use light sensors to check product quality or stage completion. 3. **Data Collection and Processing:** - **Sensor Integration:** - Write code to read data from proximity and light sensors. - **Actuator Control:** - Write code to control conveyor belt motors based on sensor data. - Implement a start/stop mechanism for the conveyor belts. 4. **Control System Implementation:** - **OpenPLC Programming:** - Develop a PLC program to manage the assembly line process. - Use ladder logic to define control actions based on sensor inputs. - **MQTT Communication:** - Publish sensor data to MQTT topics. - Subscribe to MQTT topics for control commands. 5. **Monitoring with Grafana:** - **Dashboard Creation:** - Set up Grafana to visualize real-time data from the assembly line. - Create dashboards to monitor sensor data, conveyor status, and process metrics. - **Alerts Configuration:** - Configure alerts for any process deviations or failures.

6. Data Collection - Record sensor data at each stage of the assembly line. - Monitor the status and performance of conveyor belts and other actuators.

7. Analysis - Analyze the efficiency of the assembly line process. - Identify bottlenecks and suggest improvements. - Evaluate the effectiveness of the control system.

8. Conclusion - Summarize the key components and their roles in the assembly line. - Discuss the challenges faced and how they were overcome. - Reflect on the integration of different systems to create a functional assembly line.

9. Assessment - **Quiz:** - What are the key components of an automated assembly line? - How does a proximity sensor contribute to the process? - Explain the role of MQTT in this setup. - **Practical Assessment:** - Set up and configure a new sensor in the assembly line. - Modify the OpenPLC program to add a new control action. - Create a new dashboard in Grafana to monitor the added component.