SORTING OF MATERIALS IN CNC MACHINE WITH PLC SYSTEM AND FACTORY I/O

INTRODUCTION :-

Since the world is now operating under high-speed industrial operation, efficiency, precision, and productivity are all in all. A system of colour sorting and CNC machining activities such as drilling and milling is an integrated easy manner using a 3D simulation software for industrial automation called Factory IO. This system gives a door-to-door solution about processing and transformation of raw materials into their corresponding finished products while getting the output organized efficiently, which is the harmony between smart sensing, material handling, and machining. The system starts with the input of raw materials into the production line through an emitter. The materials are conveyed forward by a belt drive, which ensures continuous and uniform movement. At the sorting stage, sensors determine the colour of each material, distinguishing between two predefined categories. The sensor's input triggers a pusher mechanism, which sends the materials to the right paths based on their colour.

Once sorted, the materials go to their respective machining centres for the operation of drilling and milling depending on the process needed for each colour. Finally, the processed materials (now products) are collected and put inside assigned boxes to ease the handling and dispatch. The entry of raw materials into the system is controlled by the emitter. The conveyor then carries these materials forward to ensure smooth movement and uniformity towards the sorting mechanism. Sensors along the conveyor accurately detect the colour of raw materials. The pusher directs materials to their respective paths depending upon the input from the sensor, which applies controlled force. Depending on their colour, the materials move on two different paths to ensure that each material goes along the correct work-flow for further processing. Materials of one colour are taken to the drilling centre, where required holes are drilled with high precision. Materials of the other colour are taken to the milling centre where they get shaped and the surface gets refined. These operations are managed by a CNC system, which produces the output with high accuracy, repeatability, and consistency. The finished products then get guided towards respective storage boxes. The separation of drilled and milled materials eases organized collection and easy retrieval for further handling or shipping. The color sorting module comes equipped with high-resolution optical sensors and intelligent AI algorithms, which identify and separate materials or products based on their colour, texture, or visual properties.

This advanced technology assures consistent and accurate sorting, drastically reducing human intervention and consequently errors in the process. Incorporated in this assembly is a machining centre providing strong capabilities for essential operations like drilling, milling, and cutting, which makes it an important part in manufacturing and assembly. By its power from the CNC technology, it ensures precise and repeatable work, rendering it an important tool within industries like automotive, aerospace, and electronics. This eliminates the need for dedicated equipment in respect to both processes. Transition from a colour sorting module to a machining module saves significant floor space—a natural and built-in benefit that means a reduction in production time. Bringing colour sorting, machining, and simulation together will provide greater benefit and help optimize your cycles and turnaround times. Secondly, this system saves a lot of waste by accurately sorting whilst combining multiple operations within the same set-up. Therefore, operational costs are minimal, with optimum utilization of resources. Sorting and machining consistency within this system means output meets and conforms to high industry standards.