PLC-Based Electro-Pneumatic Cylindrical Robot with Color Object Detection and Vacuum End Effector for Material Handling Trainer

Abstract

The problem revolves around the high cost of industrial robots, rendering them unaffordable for schools and institutions to procure. In response to this challenge, this study aims to develop a cost- efficient automated system that can provide more accurate real-world simulations by utilizing local materials. The system, named PLC-Based Electro-Pneumatic Cylindrical Robot, is used for instructional and laboratory material handling training. It includes a three-axis cylindrical robot with a vacuum end effector, achieving a versatile work envelope through motor rotations, vertical arm movements, and sliding motion. Programmed by a PLC, the robotic arm can lift objects and differentiate colors. Commissioning tests assessed the prototype's functionality, wiring, end effector efficiency, and color detection accuracy. Results revealed that all major components operated efficiently. The vacuum end effector achieved an impressive 98.33% efficiency in handling lightweight materials, while the color detection system achieved over 80% accuracy. User feedback rated the prototype as “Very Easy” to use, indicating a user-friendly experience with minimal challenges. Users strongly agreed that the system efficiently handled lightweight objects, exhibited accurate color detection, and was suitable for educational purposes. This study successfully developed an adaptable robotic trainer for material handling, demonstrating excellent performance and usability in instructional and laboratory settings. For usability, authors created a user manual for assembly, programming, wiring installation, and configuration guidance.