Automated Assembly Line Simulation Manual

Manual Book: Setting Up Raspberry Pi for OpenPLC
Automated Assembly Line Simulation
Introduction
This project-based module guides you through designing and simulating an automated assembly
line using Raspberry Pi, Arduino, and various sensors/actuators.
Objective
- Design and simulate an automated assembly line.
- Understand the integration of different components in an industrial automation system.
- Implement a basic control system to manage the assembly line process.
Background
An automated assembly line is a manufacturing process where products move through various
stages of production with minimal human intervention. Sensors and actuators ensure the process
runs smoothly and efficiently.
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
Detailed Procedure
Step 1: Setup and Configuration
Raspberry Pi Setup:
1. Connect Raspberry Pi to Network:
- Use an Ethernet cable or Wi-Fi to connect your Raspberry Pi to your network.
2. Install and Configure OpenPLC:
- Open the terminal and run the following commands:
sudo apt-get update
sudo apt-get upgrade
sudo apt-get install git
git clone https://github.com/thiagoralves/OpenPLC_v3.git
cd OpenPLC_v3
sudo ./install.sh
sudo ./start_openplc.sh
3. Verify Installation:
- Open a web browser and go to http://<Raspberry_Pi_IP>:8080 and log in with default credentials
(username: admin, password: admin).
Arduino Setup:
1. Connect Sensors and Actuators:
- Connect proximity sensors, light sensors, and motors to the Arduino.
2. Write Arduino Code:
- Open the Arduino IDE and write code to read sensor data and control actuators. For example:
void setup() {
pinMode(sensorPin, INPUT);
pinMode(motorPin, OUTPUT);
void loop() {
int sensorValue = digitalRead(sensorPin);
if (sensorValue == HIGH) {
digitalWrite(motorPin, HIGH);
} else {
digitalWrite(motorPin, LOW);
3. Upload Code:
- Upload the code to the Arduino using the Arduino IDE.
Step 2: Designing the Assembly Line
Conveyor Belt System:
1. Setup Conveyor Belts:
- Assemble miniature conveyor belts.

2. Connect Motors:
- Connect motors to control the movement of the conveyor belts. Use motor drivers if needed.
Sensor Placement:
1. Place Proximity Sensors:
- Place sensors at critical points to detect product presence.
2. Use Light Sensors:
- Use light sensors to check product quality or stage completion.
Step 3: Data Collection and Processing
Sensor Integration:
1. Write Code:
- Write Arduino code to read data from sensors and send it to the Raspberry Pi.
2. Read Data:
- Use serial communication to read sensor data on the Raspberry Pi.
Actuator Control:
1. Control Motors:
- Write Arduino code to control conveyor belt motors based on sensor data.
2. Implement Start/Stop Mechanism:
- Implement a mechanism to start/stop conveyor belts based on sensor inputs.
Step 4: Control System Implementation

OpenPLC Programming:
1. Develop PLC Program:
- Use the OpenPLC Editor to develop a PLC program to manage the assembly line process.
- Use ladder logic to define control actions based on sensor inputs.
2. Deploy Program:
- Deploy the program to the Raspberry Pi and verify functionality.
MQTT Communication:
1. Setup MQTT Broker:
- Install and configure an MQTT broker on the Raspberry Pi or another machine.
2. Publish Sensor Data:
- Publish sensor data to MQTT topics.
3. Subscribe to Control Commands:
- Subscribe to MQTT topics for control commands.
Step 5: Monitoring with Grafana
Dashboard Creation:
1. Setup Grafana:
- Install Grafana on the Raspberry Pi or another machine.
- Create dashboards to visualize real-time data from the assembly line.
2. Monitor Data:
- Monitor sensor data, conveyor status, and process metrics in real-time.

Alerts Configuration:
1. Configure Alerts:
- Set up alerts in Grafana for any process deviations or failures.
Data Collection
- Record sensor data at each stage of the assembly line.
- Monitor the status and performance of conveyor belts and other actuators.
Analysis
- Analyze the efficiency of the assembly line process.
- Identify bottlenecks and suggest improvements.
- Evaluate the effectiveness of the control system.
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.
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.

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Manual Book: Setting Up Raspberry Pi for OpenPLC

Automated Assembly Line Simulation

line using Raspberry Pi, Arduino, and various sensors/actuators.

- Design and simulate an automated assembly line.

- Understand the integration of different components in an industrial automation system.

- Implement a basic control system to manage the assembly line process.

runs smoothly and efficiently.

- Raspberry Pi with OpenPLC installed

- 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

Step 1: Setup and Configuration

1. Connect Raspberry Pi to Network:

- Use an Ethernet cable or Wi-Fi to connect your Raspberry Pi to your network.

2. Install and Configure OpenPLC:

- Open the terminal and run the following commands:

sudo apt-get update

sudo apt-get upgrade

sudo apt-get install git

git clone https://github.com/thiagoralves/OpenPLC_v3.git

(username: admin, password: admin).

1. Connect Sensors and Actuators:

- Connect proximity sensors, light sensors, and motors to the Arduino.

2. Write Arduino Code:

int sensorValue = digitalRead(sensorPin);

- Upload the code to the Arduino using the Arduino IDE.

Step 2: Designing the Assembly Line

Conveyor Belt System:

1. Setup Conveyor Belts:

- Assemble miniature conveyor belts.

1. Place Proximity Sensors:

- Place sensors at critical points to detect product presence.

2. Use Light Sensors:

- Use light sensors to check product quality or stage completion.

Step 3: Data Collection and Processing

- Use serial communication to read sensor data on the Raspberry Pi.

2. Implement Start/Stop Mechanism:

- Implement a mechanism to start/stop conveyor belts based on sensor inputs.

Step 4: Control System Implementation

1. Develop PLC Program:

- Use ladder logic to define control actions based on sensor inputs.

- Deploy the program to the Raspberry Pi and verify functionality.

1. Setup MQTT Broker:

- Install and configure an MQTT broker on the Raspberry Pi or another machine.

2. Publish Sensor Data:

- Publish sensor data to MQTT topics.

3. Subscribe to Control Commands:

- Subscribe to MQTT topics for control commands.

Step 5: Monitoring with Grafana

- Install Grafana on the Raspberry Pi or another machine.

- Create dashboards to visualize real-time data from the assembly line.

- Monitor sensor data, conveyor status, and process metrics in real-time.

- Set up alerts in Grafana for any process deviations or failures.

- Record sensor data at each stage of the assembly line.

- Analyze the efficiency of the assembly line process.

- Identify bottlenecks and suggest improvements.