Low Cost Conveyor Line Solution: Monolithic Control Circuit and Selection Analysis

​How can a small factory automate on a tight budget?Don't panic! Let's break down how to use it in the most down-to-earth way today!Microcontroller + Cabbage AccessoriesBuild a reliable conveyor line system. After reading this you too can do great things with little money and your boss will praise you for your ability to make a living!

First, why do you have to use a microcontroller? Save not a little bit!

​Core question: with PLC or microcontroller? How much is the difference?​
The answer.Costs cut in half to start withI don't think so! Let's do the maths:

• ​PLC programme: A basic PLC set is less than $2000, plus modules running at $5000!
• ​Microcontroller programme: STM32 microcontroller core board 50, driver module 30, sensor 20...Full hardware in 300.​
  Not to mention the post maintenance - PLC change a module meat pain, microcontroller burned directly replace the board, milk tea money is not enough!

​Key reminders: Monolithic is not synonymous with low-end! Like page 5 saysLow-cost automation ≠ low technologyThe microcontroller is more flexible than a PLC when used properly. For example, change a sorting logic, PLC to rewrite the programme burn, microcontroller plug computer to change two lines of code to get it done.

Second, the core circuit design: three strokes to deal with drive + sensing

​Q: Circuit whizzes are afraid of wiring the board wrong and burning it?​
Grab these three core modules and the package will light you up in one go:

1. ​Drive module - the "accelerator" of the motor​
   • ​MOS tube + H-bridge: Costs $10 and drives a 500W motor with no stress
   • ​Tips to prevent burning: Remember to addrefill diode! Otherwise the reverse current will send you up in smoke in minutes when the motor stops (don't ask how you know...)
2. ​Sensor modules - the "eyes" of the system​
   

   Sensor type	(manufacturing, production etc) costs	Applicable Scenarios	Installation Tips
   electro-optical counterpoint	8 yuan/pair	Counting/positioning (accuracy ±1mm)	Alignment needs to be spot on. Dust needs to be wiped off.
   dipswitch	2 yuan	Manual setting of sorting destination	Choose the one with a lock to prevent accidental contact
   pressure sensing	Fifteen.	Overweight alarm	Most sensitive when attached to the underside of the motor shaft

3. ​Power modules - don't save for tragedy!​
   Lesson learnt in blood: motor starting current soared 3 times!Power = (sum of all motor powers x 3) x 1.5This is the formula for saving life. Page 4 case of a factory to save money on power supply, the result of bulk burn board rework loss of 60,000

Third, the selection of pit guide: these money should not be spent!

​Q: Do I choose belts or rollers for conveyor belts?​
Look at the material and talk! Refer to page 9 of theFour-dimensional selection method::

1. ​small lightweight(mobile phone case/small package): selectPU belt line​
   • Pros: quiet and cheap, easy to redirect
   • Pit point: don't choose too thin! 0.8mm thick to start with, or half a year to wear through!
2. ​Heavy goods/pallets(Hardware/case goods): closed-eye selectionNon-Powered Roller​
   • Gravity rolls on, electricity costs the province! A classic example of Page 5: Ramp + Roller combination with 0 energy consumption for 30 metres of conveying
   • Key parameters: roller spacing ≤ cargo length / 2 (otherwise jammed to you doubt life)
3. ​special environment(Wet area/oil stains).Stainless steel chain plate lineIt's the only solution.
   • More expensive but durable, galvanised don't consider! Webpage 11 real test: galvanised chain plate soaked in water for 3 months rust through, stainless steel with 5 years is fine!

IV. The essence of programme design: less is more!

Web 5gravity-defying operation::

"Material handling processesNo electric drive requiredThe design is based on gravitational potential energy + mechanical design alone, and lets the material fly."
Hands-on programmes:

1. ​climbing section: Short-pitch belt line lift (200 W power option is sufficient)
2. ​transport section: Stainless steel roller with 3° inclination angle, sliding under its own weight.
3. ​Tips for controlling speed: Addition to the drum shaftFriction disc damper(cost 50 cents), 20 times cheaper than an inverter!

​Personal experience of stepping into the pitDon't be obsessed with full automation! A customer has to learn from the big manufacturers to engage in AGV docking, the result is stuck in the positioning accuracy burned 80,000 yuan. In fact, with the web page 10Semi-automatic programme: Manual stocking + automatic sorting, the cost is pressed to 1/10, but more efficient.

V. Commissioning Tips: 5 Mantras for a Less Detoured Road

1. ​"Adjust the bare board before connecting the motor."--I don't want you to experience the pain of burning the driver board by reversing the wires.
2. ​"Keep sensors away from strong wires."-Interference false trigger? Keep 20cm distance to solve the problem
3. ​"The encoder must be shielded."--A signal line without a magnetic loop is an antenna, designed to pick up workshop clutter.
4. ​"Dual redundancy of emergency stop buttons."--This is not advice it's life saving! Lessons from Page 7: Single Button Failure Leads to Crashes
5. ​"Weekly dusting is like brushing your teeth."--Photoelectric sensor dust? Cotton swabs dipped in alcohol wipe, than to replace the new one works for ten years!

A personal argument: don't be crippled by the "high end"!

I have seen too many factories superstitious imported PLC, robots, the results of the capacity did not get up first back a debt.SMEs' core claim is to surviveWeb 5 says it all: "Low-cost automation achieves 80% performance at 20% cost"! Page 5 says it all: "Low-cost automation with 20% cost to achieve 80% performance" is the way to go.

Take a real case: a hardware factory in Zhejiang uses STM32+ gravity roller line.Total investment is less than 20,000, replacing a PLC conveyor line originally planned for $200K:

• Combination of dip switches + photoelectric sensors for sorting (cost $200)
• Speed control by PWM voltage regulation module ($30)
• ​Half a year's paybackThe boss paid double year-end bonuses for the money he saved.

Next time anyone tells you "no PLC unprofessional", throw the bill in their face.What you save is profit. Survival is the future.!