ROBO 366 – Design Project and Development 2 – Final Technical Report 1

Final Report - Metal Sense PRO

Kurtis Rozmahel (301216412)

Rahul Kumawat (301311776)

Raheel Lathiya (301213520)

Sagarbhai Jayswal (301399021)

Alejandro Verde Morales (301371271)

Centennial College

School of Science and Technology

Department of Automation and Robotics

ROBO366-003

James Cook

Furong Tan

Date: 04/12/2025
ROBO 366 – Design Project and Development 2 – Final Technical Report 2

Declaration of Group Authorship

We, Kurtis Rozmahel, Rahul Kumawat, Raheel Lathiya, Sagar Bhai Jayswal, and

Alejandro Verde Morales, confirm that this breakdown of authorship represents our

contribution to the work submitted for assessment, and our contribution is our work and

is expressed in our own words. Any uses made within the Technology Report of the

works of any other author, separate from the work group, in any form (ideas, equations,

figures, texts, tables, programs), are properly acknowledged at the point of use. A list of

the references used is included.

Name Sections Completed Signature

Kurtis Rozmahel Abstract and Conclusion

Rahul Kumawat Introduction and Gantt Chart

Raheel Lathiya Calculations and Formatting

Sagar Bhai Jayswal Electrical Circuit and Results

Alejandro Verde Design and Appendices

Morales

Date: 04/12/2025
ROBO 366 – Design Project and Development 2 – Final Technical Report 3

Abstract

The Metal Sense PRO project is the development of a conveyor system with metal and

non-metal part sorting functionality. The system was made by incorporating an inductive sensor

and pneumatic cylinder onto a conveyor and connecting everything within a PLC program. The

system comes equipped with safety functionality, including an MCR, E-stop, and light indicators.

Throughout the project, the design is seen to have varied from the initial concept by a large

amount. The final design ended up only using a single sensor and cylinder to sort the two

distinguishable parts. The performance of the project was a success as the system was able to

accurately sort all fed metal and non-metal parts into their respective collection bins. The

simplicity of the design has the benefit of being easy to troubleshoot, but has the drawback of

low flexibility when it comes to the shape and size of parts being sorted. Further improvements

would include adding functions and altering the design in a way that allows for sorting of a wider

range of parts.
ROBO 366 – Design Project and Development 2 – Final Technical Report 4

Table of Contents

1. Cover Page ………………………………………………………..……….. 1.

2. Declaration of Group Authorship ………………………………..………. 2.

3. Abstract ……………………………………………………………….…… 3.

4. Table of Contents ……………………………………………….…………. 4.

5. List Of Illustrations …………………………………………….…………. 5.

6. Introduction ………………………………………………………………. 6.

7. Design …………………………………………………………………. 07-08.

8. Results and Analysis …………………………………………………. 09-11.

9. Conclusion ………………………………………………………………… 11.

10. Recommendations ……………………………………………………….. 12.

11. References ………………………………………………………………… 13.

12. Appendices …………………………………………………………….. 14-29.

A. Mechanical Drawing ……………………………………………… 14-15.

B. Electrical Circuit …………………………………………………… 16-19.

C. Pneumatic Schematic …………………………………………………. 20.

D. PLC Program ………………………………………………………….. 21.

E. Cycle Time Calculation …………………………………………….. 22-23.

F. Project Expenses ……………………………………………………….. 23.

G. Gantt Chart ……………………………………………………………... 24.

H. Project Timeline ……………………………………………………. 25-29.

ROBO 366 – Design Project and Development 2 – Final Technical Report 5

List of Illustrations

Figure 1. Final Flow Chart of the Complete Process …………………………………. 09.

Figure A.00 Metal Sense PRO Design (Top, Front and Side View) ……………….… 14.

Figure A.01 Metal Sense PRO Overall Dimensions with B.O.M …………………….. 14.

Figure A.02 3D Part - Feed Parts Guide Rail ………………………………………….. 15.

Figure A.03 3D Part - Sensor and Cylinder Holder …………………………………… 15.

Figure B.00 Metal Sense Pro – Electrical Safety Circuit ……………………………….. 16.

Figure B.01 Metal Sense Pro – Digital Input Circuit 01 ………………………………... 17.

Figure B.02 Metal Sense Pro – Digital Input Circuit 02 (Not Used) …………………… 18.

Figure B.03 Metal Sense Pro – Digital Output Circuit …………………………………. 19.

Figure C.00 Pneumatic Circuit ……………………………………………………………. 20.

Figure D.00 PLC Program …………………………………………………………………. 21.

ROBO 366 – Design Project and Development 2 – Final Technical Report 6

Introduction

The Metal Sense PRO project is the development of a reliable sorting system that acts as

a method to reject metal parts from a process. The objective of the project was to design the

system using technology and standards that are present in the automation industry. This result is

a system that uses a programmed PLC, sensors, and actuators to achieve its goal. The Metal

Sense PRO system also includes safety functionality seen on industry machines, such as an MCR

that deactivates upon the press of an emergency stop, which will prevent the system from

restarting until the MCR is reset with a labelled pushbutton.

A light system is also present to show the status of the system, and indicates whether the

MCR needs to be reset. Using this equipment, the goal is to separate oncoming parts depending

on whether they are made out of metal or non-metal. Therefore, the project uses engineering

principles such as an inductive sensor to differentiate metal parts from the rest and a solenoid-

actuated directional control valve (DCV) to direct air into a pneumatic cylinder, which pushes

desired parts to a separate location. The operation, light system, and safety functions are all

interconnected through the PLC program. This allows the operator to control the machine, safely

stop it from running in case of emergency, and see the status of the operation with the light. To

determine whether the developed system is a success, an experiment will be run where metal and

non-metal parts are fed onto the conveyor, and two collection bins will be placed for the two

distinct types of parts.

The experiment is to see whether the system pushes all of the metal parts off of the

conveyer into the first collection bin and let the non-metal parts continue into a collection bin at

the outlet of the conveyer, upon which it will be determined if the Metal Sense PRO project is a

success, or if there is still room for improvement.

ROBO 366 – Design Project and Development 2 – Final Technical Report 7

Design

Determining the essential functional criteria for developing an automated system that

identifies and separates metal and non-metal components was the first step in the Metal Sense

PRO project's design process. A modular conveyor-based sorting machine with sensors,

actuators, and a programmable logic controller (PLC) was the cornerstone of the system design.

Each component was carefully selected and put into place based on compatibility, performance,

and industry relevance.

Its strong functionality and flexibility in ladder logic programming led to the selection

of the Omron CP1L PLC for control logic and I/O management. An inductive proximity sensor,

which has a high response frequency for detecting metal, was utilized to find metallic particles

on the conveyor. Metal components were to be ejected from the conveyor line using a pneumatic

cylinder that was driven by compressed air and managed by a solenoid directional control valve.

Consistent material flow for the items being inspected was provided by a DC-powered conveyor

system.

To make modifications easier and guarantee a clear division between functional areas like

sorting, detection, and collection, the complete system was developed in SolidWorks utilizing a

modular approach. Guide rails and sensor/piston mounting brackets were among the specially

made components that were 3D printed after being modelled in CAD. As a result, important

sensor and actuator interfaces were precisely aligned and robustly assembled.
ROBO 366 – Design Project and Development 2 – Final Technical Report 8

Relays, 6-amp circuit breakers, and indicator lights were among the common industrial

parts used in the electrical circuit (Masar, 2023). With an MCR (Master Control Relay) acting as

a safety interlock, wiring was meticulously routed from the control panel to every device. When

the emergency stop button was hit, the MCR would turn off all outputs and could only be reset

using a specific pushbutton.

CX-Programmer was used for programming, and a comprehensive sequence was created

to manage system failures, regulate the pneumatic ejection cylinder, and monitor sensor

conditions (GARY, 2003). The ladder logic made use of timers and flags to guarantee safe

operation and timely activation. The team was able to optimize PLC logic and guarantee

dependable detection and sorting during testing and debugging phases

The appendices' comprehensive mechanical drawings, schematics, and part lists

contributed to the design's overall readability and clarity. This ensured that every facet of part

assembly, circuit wiring, and programming was well documented for future duplication or

enhancements.
ROBO 366 – Design Project and Development 2 – Final Technical Report 9

Results and Analysis

For the final design, it is apparent that a few things changed compared to the initial

concept. Before the preliminary design, the idea was to separate the two groups of parts (metal

and non-metal) on the conveyor into their own path, which led to individual downstream

conveyors. This concept required the use of two pneumatic cylinders and three conveyors. After

consideration, it was determined that this concept was out of the scope and budget of this project,

and the design was simplified to require only one conveyor and one cylinder. This led to the

creation of the preliminary design, which is much closer to the final design. The preliminary

design followed the same logic as the final design, where metal parts were picked up by an

inductive sensor, and rejected off the conveyor into a collection bin by a cylinder. Differences

include placements of the sensor and cylinder, and the control panel layout.

Figure 1. Final Flow Chart of the Complete Process

ROBO 366 – Design Project and Development 2 – Final Technical Report 10

Calculations were done to confirm mechanical and temporal feasibility to help the design

process. For instance, the conveyor speed and part spacing were used to calculate the sorting

cycle time. With a target of around 7 parts each cycle and a conveyor length of 920 mm, and a

belt speed of 50 mm/sec, the projected cycle time per part was 1.3 seconds. The pneumatic

actuator also underwent force analysis, which revealed that 10.13 N of force was needed to push

items off the conveyor without jamming. Also, the range of the inductive sensor is 8 mm

(ELSEVIER, June 1995, pp. 179-188).

Object sorting is a practical function when it comes to automation, as it allows processes

to differentiate between wanted and unwanted parts. In the case of Metal Sense PRO, it was

decided to develop an object sorting system that distinguishes metal from non-metal parts. The

resulting design ended up being functional and reliable when experimented on. The experiment

involved feeding two distinctive metal and non-metal parts in a random sequence and observing

whether all the parts were sorted into their respective collection bins. The result was 100%

accurate, as the system did not fail to push a single metal part off the conveyor into its bin.

This final design for the project has both positive and negative aspects. Overall, the

system is simple, which has benefits and limitations. For example, the simplicity of the design

makes it easy to troubleshoot, as there are not many aspects that can be adjusted. When the

cylinder was actuating too soon, jamming the system instead of pushing the part, the only

adjustment that could be made was the timing in the PLC program, and the system rejected

reliably after the timer was increased. However, there are many limitations to this design. For
ROBO 366 – Design Project and Development 2 – Final Technical Report 11

example, with a fixed guide at the infeed of the conveyor and the part having to be positioned

right next to the sensor to activate it, any part too small can easily be fed too far from the sensor

to get picked up. The feed parts also must be large enough not to go under the sensor or cylinder.

This makes the system have a very small tolerance for the sorted parts' size, which limits the

application.

Conclusion

In conclusion, Metal Sense PRO is a reliable metal and non-metal sorting system that was

developed using concepts and technology present in the industry. The conveyor system uses an

inductive sensor and a pneumatic cylinder to reject metal parts into a separate collection bin.

This system includes full safety functionality such as an MCR with a reset pushbutton, E-stop,

and a status indicator light, all incorporated into a PLC program that runs the operation. The

success of the project was determined by running an experiment where many metal and non-

metal parts were fed onto the conveyor and observing whether they were all collected into the

proper bins. This experiment yielded 100% accurate sorting results. When comparing the design

to the initial concept, it is seen that the final product largely differs, as it was simplified to use

only one sensor, cylinder, and conveyor. This final design comes with the benefit of being easy to

service and troubleshoot, but has the limitation of being inflexible about the size or shape of the

parts it sorts.
ROBO 366 – Design Project and Development 2 – Final Technical Report 12

Recommendations

 Within the project's scope and budget, the finished result was deemed successful.

 If further work is done, some enhancements could be possible. The usefulness of the

existing system is limited since it only sorts metal and non-metal pieces.

 A counter and a display for rejected metal components are examples of extra

functionality that might be included.

 A greater variety of part sizes and shapes might be accommodated by altering the design.
ROBO 366 – Design Project and Development 2 – Final Technical Report 13

Reference

ELSEVIER. (June 1995). Volume 15, Issue 3. In ELSEVIER, Measurement (pp. 179-188).

ELSEVIER.

GARY. (2003, June 30). Basics of Omron CX Programmer. Retrieved from CONTROL.COM:

https://control.com/forums/threads/basics-of-omron-cx-programmer.13243/

Masar, P. (2023, October 25). Electrical Controls & Indicators. Retrieved from revain.com:

https://revain.com/guides/electrical-controls-and-indicators-types-functions-and-

importance-in-industrial-automation-systems
ROBO 366 – Design Project and Development 2 – Final Technical Report 14

Appendices

A. Mechanical Drawings

Figure A.00 Metal Sense PRO Design (Top, Front, and Side View)

Figure A.01 Metal Sense PRO Overall Dimensions with B.O.M

ROBO 366 – Design Project and Development 2 – Final Technical Report 15

Figure A.02 3D Part - Feed Parts Guide Rail

Figure A.03 3D Part - Sensor and Cylinder Holder

ROBO 366 – Design Project and Development 2 – Final Technical Report 16

B. Electrical Circuits

Figure B.00 Metal Sense Pro – Electrical Safety Circuit

ROBO 366 – Design Project and Development 2 – Final Technical Report 17

Figure B.01 Metal Sense Pro – Digital Input Circuit 01

ROBO 366 – Design Project and Development 2 – Final Technical Report 18

Figure B.02 Metal Sense Pro – Digital Input Circuit 02 (Not Used)
ROBO 366 – Design Project and Development 2 – Final Technical Report 19

Figure B.03 Metal Sense Pro – Digital Output Circuit

ROBO 366 – Design Project and Development 2 – Final Technical Report 20

C. Pneumatic Schematic

Figure C.00 Pneumatic Circuit

ROBO 366 – Design Project and Development 2 – Final Technical Report 21

D. PLC Program

Figure D.00 PLC Program

ROBO 366 – Design Project and Development 2 – Final Technical Report 22

E. Cycle Time Calculation:

• Omron SYSMAC CP1L PLC

• Power Source:

Input voltage: 110VAC, 60Hz, 1.3Amp

Output Voltage: 24VDC, 3.0Amp

• Fuse rating: 110v -6Amps

• Inductive sensor: PNP, 1000Hz, Normally Open, 24 VDC, 200 mA

• Conveyor description: (from product description)

- 24VDC

- Total Length 920 mm

- Total Width 100 mm

- Motor RPM = 30 rpm

- Belt speed = 50 mm/sec

- Max capable load on conveyor = 3.5 kg

• Force generated by the cylinder

=AxP

=0.0314 x 72.5

=2.28 lbf

=10.13 N

 Parts dimension = 60 x 60 mm (including metal and non-metal parts).

So, possible parts on the conveyor

= (920/2)/60
ROBO 366 – Design Project and Development 2 – Final Technical Report 23

= 7.66 (possible parts)

Cycle time for sorting = (total belt length/2) / (belt speed)

= (920/2) / (50)

= 9.12 sec

Cycle time for sorting of 1 part is 9.12/7 = 1.3 sec.

F. Project Expenses:

Total Expense: 169.87 $

ROBO 366 – Design Project and Development 2 – Final Technical Report 24

G. Gantt Chart
ROBO 366 – Design Project and Development 2 – Final Technical Report 25

H. Project Timeline

 Week 1

Define Project Subject:

• Finalized the project topic through discussions and research with guidance
from Professors
• James Cook and Tan Furong.
• Team Members Involved: All (Rahul, Sagar, Raheel, Kurtis, Alejandro).
• Timeline: Started 10-Jan-2025, finished 12-Jan-2025 (2 days).
1. Project Research:

• Conducted research on project feasibility using Thingiverse and feedback

from Professor James
• Cook.
• Team Members Involved: All (Rahul, Sagar, Raheel, Kurtis, Alejandro).
• Timeline: Started 10-Jan-2025, finished 14-Jan-2025 (0.5 week).
2. Rough Concept:

• Developed an initial project concept through brainstorming sessions.

• Team Members Involved: All (Rahul, Sagar, Raheel, Kurtis, Alejandro).
• Timeline: Started 10-Jan-2025, finished 12-Jan-2025 (2 days).
3. Milestone 1:

• Achieved the first project milestone, ensuring project requirements and

feasibility.
• Team Members Involved: Rahul and Sagar.
• Timeline: Started 10-Jan-2025, finished 17-Jan-2025 (1 week).

 Week 2

4. Parts Collection:

• Started gathering required project parts from the college and external
sources. (70%
• complete).
• Team Members Involved: Kurtis and Rahul.
• Timeline: Started 17-Jan-2025, finished 27-Jan-2025 (10 days).
ROBO 366 – Design Project and Development 2 – Final Technical Report 26

5. Perform Calculations:

• Conducted technical calculations to verify system feasibility.

• Team Members Involved: Raheel and Sagar.
• Timeline: Started 17-Jan-2025, finished 20-Jan-2025 (3 days).
6. BOM Purchase or Make Decision:

• Decided which components to buy and which to fabricate.

• Team Members Involved: Sagar and Raheel.
• Timeline: Started 17-Jan-2025, finished 19-Jan-2025 (2 days).
7. Purchase Raw Materials:

• Began ordering raw materials from AliExpress and Amazon.

• Team Members Involved: Raheel.
• Timeline: Started 17-Jan-2025, ongoing (3 weeks).

 Week 3

8. Mechanical Design:

• Created detailed mechanical designs using SolidWorks.

• Team Members Involved: Alejandro.
• Timeline: Started 24-Jan-2025, finished 30-Jan-2025 (1 week).
9. Circuit Design:

• Developed circuit diagrams using AutoCAD, ensuring compatibility with

mechanical
• components.
• Team Members Involved: All (Rahul, Sagar, Raheel, Kurtis, Alejandro).
• Timeline: Started 24-Jan-2025, finished 29-Jan-2025 (5 days).

 Week 4

10. Milestone 2:

• Successfully completed the second milestone, ensuring that the system

design and
• procurement phases were finalized.
• Team Members Involved: Sagar and Raheel.
ROBO 366 – Design Project and Development 2 – Final Technical Report 27

• Timeline: Started 24-Jan-2025, finished 30-Jan-2025 (1 week)

 Week 5
11. Assembly and Programming:
 Assembly: Conducted physical assembly of components in the machine
shop.
 Team Members Involved: All (Rahul, Sagar, Raheel, Kurtis, Alejandro).
 Timeline: Started 31-Jan-2025, finished 7-Feb-2025 (1 week).
12. Wiring:
 Connected system components through proper wiring techniques.
 Team Members Involved: Rahul, Sagar, Raheel.
 Timeline: Started 31-Jan-2025, finished 2-Feb-2025 (2 days).
13. Programming:
 Developed program logic using CX-Programmer.
 Team Members Involved: Kurtis, Raheel.
 Timeline: Started 31-Jan-2025, finished 2-Feb-2025 (2 days).
14. Milestone 3:
 Completed third milestone confirming mechanical-electrical
integration.
 Team Members Involved: All.
 Timeline: Started 31-Jan-2025, finished 7-Feb-2025 (1 week).
 Week 6
15. Mechanical Assembly Drawings:
 Created 2D/3D assembly drawings using SolidWorks.
 Team Members Involved: Raheel, Kurtis, Alejandro.
 Timeline: Started 14-Feb-2025, finished 21-Feb-2025 (1 week).

 Week 7
16. Electrical Circuit Schematics:
 Designed the electrical schematics using AutoCAD.
ROBO 366 – Design Project and Development 2 – Final Technical Report 28

 Team Members Involved: Rahul.

 Timeline: Started 21-Feb-2025, finished 25-Feb-2025 (4 days).

17. Milestone 4:
 Verified design documentation for milestone submission.
 Team Members Involved: All.
 Timeline: Started 14-Feb-2025, finished 28-Feb-2025 (2 weeks).

 Week 8
18. First Motion:
 Performed initial motion tests of the system components.
 Team Members Involved: All.
 Timeline: Started 28-Feb-2025, finished 7-Mar-2025 (1 week).

 Week 9
19. Troubleshooting:
 Identified and resolved errors in mechanical and electrical
components.
 Team Members Involved: All.
 Timeline: Started 7-Mar-2025, finished 14-Mar-2025 (1 week).

 Week 10
20. Troubleshooting (Continued):
 Continued debugging for stable system operation.
 Team Members Involved: All.
 Timeline: 14-Mar-2025 to 21-Mar-2025 (1 week).

 Week 11
21. Milestone 5:
 Presented the working prototype for evaluation and validation.
ROBO 366 – Design Project and Development 2 – Final Technical Report 29

 Team Members Involved: Raheel, Kurtis, Alejandro.

 Timeline: Started 28-Feb-2025, finished 21-Mar-2025 (3 weeks).

 Week 12
22. Final Testing and Modifications:
 Executed final tests and made improvements based on feedback.
 Team Members Involved: All.
 Timeline: Started 21-Mar-2025, finished 28-Mar-2025 (1 week).

 Week 13
23. Report Submission:
 Submitted the technical and progress report using Luminate format.
 Team Members Involved: All.
 Timeline: Started 28-Mar-2025, finished 11-Apr-2025 (2 weeks).
24. Presentation Preparation:
 Prepared slides and practiced for final presentation.
 Team Members Involved: All.
 Timeline: Started 4-Apr-2025, finished 6-Apr-2025 (2 days).

 Week 14
25. Project Demonstration:
 Live demonstration of the final project to faculty and evaluators.
 Team Members Involved: All.
 Timeline: 11-Apr-2025 (1 day).