CAD Journaling: Extra Part

This is an extra part for my CAD journaling.

I want to share what I did to create this 3D project. It was really easy.

I used 2020 aluminum profiles, which saved me some work. The main thing I focused on was carefully measuring dimensions and making some additions, like drive pulley supports for the tubes and the tubes themselves.

There isn’t much else to add here since it was quite easy. I tried to focus mostly on the automation part.

Overall, it wasn't difficult because it’s pretty simple and is related to the basics of Fusion360.

Project Conclusion: Searching for Fixes

In this final stage, I focused on looking for fixes. Fortunately, I didn't find anything major.

Since I paid for the project myself, I didn't have to worry about costs.

Additionally, I made a PCB board for the PLC controller by myself (haters will hate 😏).

I am really happy with the entire project — it succeeded!

My colleagues from the profile also liked it.

I cannot wait to add the fully built project.

Key Points

• No major fixes were needed
  
• Self-funded project — no cost worries
  
• Designed a custom PCB for the PLC controller
  
• Project was a success and well-received
  

"Haters will hate " — but progress doesn't stop for them!

Thanks...

PCB routing and finishing the board design

I’ve moved on to the PCB stage and finished connecting everything on the board.

The whole process took me about 1.5 hours.

I also added my own custom routing to make the board look cleaner and more organized, while keeping it optimized for the project’s needs.

With this, the PCB design is now complete.

Finished the full schematic

I’ve now completed the entire schematic.

Since I’m not a fan of copy-and-paste design, I added several custom elements of my own — things like LEDs, contacts, and a few extra details to make the project more functional.

I’m also planning to use different resistor values tailored to the project, along with different relays that can handle higher currents.

All of this took me around 3.5 hours to put together, and I’m pretty happy with how it turned out.

Starting the PLC build — schematic phase

I’ve begun working on the schematic for my PLC.

Since I’m studying as an automation technician, I already understand how PLCs work, which made building the schematic much easier.

I used some OSHW examples as references, but I still built everything myself.

Copy-paste without adding your own ideas feels pointless, so I removed a few unnecessary elements and added several important and interesting ones — improvements to the layout, some optimizations, and adjustments to the inputs.

The PCB design for the PLC is being created in KiCad, and the project is slowly taking shape.

idea for a custom PLC

Recently I came up with the idea of creating my own PLC.

Instead of buying an expensive industrial controller, I could build one myself using an ESP32.

The plan looks like this:

• program it using OpenPLC, so the software side stays straightforward,
• design my own PCB, since this is meant to be a real hardware project,
• keep the overall cost much lower than purchasing a ready-made PLC.

I’m starting the development soon and I’m curious to see how far I can take this project.

Finishing Project

At this stage, I focused on setting up the GitHub repository and carefully checking if everything works correctly.

Luckily, I didn’t find any issues or gaps in the project.

Creating the BOM

At this stage, getting close to finishing the project, I focused on creating the full BOM.

I wanted the list to be clean, realistic, and based on components that will actually work well together in a small industrial-style sorting system.

Below is the complete list of selected components.

## 1. Sensors

Grove Ultrasonic Distance Sensor

• Quantity: 2
  
• Unit Price: 47 PLN
  
• Total: 94 PLN
  

2. Pneumatics

Polyurethane Pneumatic Hose PU 8/5 mm

• Quantity: 1
  
• Price: 4 PLN
  

FRL Filter (1/4″)

• Quantity: 1
  
• Price: 86 PLN
  

AirTAC NAMUR 5/2 Solenoid Valve (G 1/4, 230V)

• Quantity: 2
  
• Unit Price: 192 PLN
  
• Total: 384 PLN
  

Pneumatic Cylinder 32×200 mm (Double-acting)

• Quantity: 1
  
• Price: 310 PLN
  

3. Motion System

Stepper Driver (for NEMA 16/17/23/24, up to 5.6 A)

• Quantity: 1
  
• Price: 90 PLN
  

NEMA23 Stepper Motor (2 Nm, 3 A, 57HS76-3004A08)

• Quantity: 1
  
• Price: 118 PLN
  

4. Power & Protection

DIN-rail Power Supply 24 V / 15 W (Qoltec)

• Quantity: 1
  
• Price: 49 PLN
  

Circuit Breaker HN-C20/1

• Quantity: 1
  
• Price: 23 PLN
  

5. Control (HMI Basics)

ONPOW LAS0-B3Y-11/R (Red, NO/NC)

• Quantity: 2
  
• Unit Price: 20 PLN
  
• Total: 40 PLN
  

6. Structural Components

2020 Aluminum Profiles (6 meters total)

• Quantity: 1 set
  
• Price: 340 PLN
  

📦 Total Cost Summary

Im paying by myself so i dont care about costs ;P

Controller Upgrade – Switching to Siemens S7-1200

After reviewing my options, I decided to replace the LOGO! controller with a Siemens S7-1200. I came across a good offer, and considering long-term use, the S7-1200 provides significantly better performance and flexibility.

The previous LOGO! setup worked well for basic testing, but ultimately it is still classified as a “programmable relay.” The S7-1200, on the other hand, is a full PLC with more advanced features, better expansion capabilities, and improved reliability.

This upgrade should give the entire system a more professional foundation and allow for future improvements without hitting hardware limitations too early.

Adding Place for sorted items

In this stage, I worked on the area where the sorted items will slide down. After seeing the photo, you may wonder why it is positioned so far away.

While I was setting the actuator values and looking for the best option, I chose the actuator with the best piston force (also known as actuator thrust force in pneumatics). Because of this, the actuator can easily handle the task and push the item without any issues.

It took me about half an hour.

Optimizing V2

At this stage, I focused on visual improvements as well as optimizing the profiles and overall 3D structure. These adjustments helped make the design clearer, more refined, and more functional.

What Has Been Improved

• Drive pulley enhancement – I redesigned the drive pulley to ensure smoother and more stable rotation on the motor, which should improve performance under load.
• Code optimization – I updated the code to reduce the risk of short circuits during heavy load conditions, increasing the system’s safety and reliability.

Calculation Verification

Objective

I focused on verifying all the necessary calculations for my project. I analyzed the forces involved in handling objects of various materials and weights, as well as the energy requirements and motor power.

These calculations are crucial to ensure the sorter operates correctly and reliably.

Process

• Checking the numbers at this stage was essential to make sure the system would work properly.
  
• I verified the power of my motors and actuators to prevent overloading (in fact, I was confident nothing would happen, as I had already checked everything).
  
• I tested the frame in a simulator to ensure it wouldn't break — luckily, nothing did (at least I think so, lol).

Efficiency

The entire process was completed in 30 minutes, which allowed me to quickly confirm the correctness of the project and prepare for the next stages of building the system.

PLC Learning and Testing

Since PLC hardware was not available at the school yet, the Siemens LOGO! PLC with 24 V DC relay modules was used for learning and testing purposes.

Key steps included:

• Reading relevant documentation to understand module connections and wiring points.
  
• Hands-on testing in Factory I/O to simulate the PLC and practice clean programming techniques.
  
• Creating structured, reliable code that improved on an earlier prototype.
  

The learning process took roughly an two hours and provided practical insight into both wiring and programming the LOGO! PLC, helping to prepare for real hardware integration later.

Pneumatic System Components

Components used

• Cylinders: 2× 32×200 mm double-acting, magnetic pistons included for optional position sensing.
  
• Solenoid valves: 2× 5/2 monostable, 24 V DC, one for each cylinder. They can connect directly to LOGO! outputs or through a relay if more current is needed.
  
• FRL unit: 1× 1/4" Filter-Regulator-Lubricator. It cleans air, regulates pressure, and provides light lubrication.
  
• Flow control valves: Optional, used to adjust cylinder extend/retract speed.
  
• Air supply: Standard compressor with tank, delivering ~6 bar, providing enough flow for both cylinders at the same time.
  
• Tubing & fittings: PU hoses Ø6–8 mm with push-in fittings.
  

Component selection process

Components were chosen based on compatibility and reliability:

• Cylinders were picked for their bore and stroke, ensuring double-acting operation.
  
• Solenoid valves were selected for 24 V DC operation and one-to-one cylinder control.
  
• FRL size (1/4") was based on the required flow for both cylinders.
  
• Flow control valves allow for fine adjustments of piston speed.
  
• Tubing and fittings were chosen for ease of installation.
  

Overall, the setup uses standard pneumatic components to ensure reliable operation and simple integration with a Siemens LOGO! PLC.

Looking for the best cylinders for my compressor

Pneumatic Cylinder Setup

So I’ve been messing around with a small pneumatic cylinder for a home project and thought I’d jot down what I did.

What I needed

• 150 mm stroke
  
• Single-acting (spring return)
  
• Light cushioning at the end
  
• Just screw it onto some aluminum profiles
  
• Speed doesn’t really matter
  
• Home-use, nothing fancy
  
• Pushing very light stuff (max ~1 kg)
  
• My small compressor seems to handle it fine

Picking the cylinder

Honestly, for something this light, almost any small cylinder will do. The force depends on the pressure and piston size, roughly like this:

Even a tiny 16 mm cylinder at 6 bar can easily push 12 kg, so my 1 kg load is trivial. The cylinder volume per stroke is tiny, so my little compressor has no problem keeping up.

Super simple, nothing fancy.

Unfortunately, I didn't find any cheap single-acting ones, so I took double-acting ones.

PLC Programming

At this stage, I was responsible for writing the code for the Siemens LOGO PLC for the entire project.

I implemented the program in CODESYS using the Ladder Diagram (LD) language.

Thanks to my experience with LD, I didn't encounter many problems during this process.

In fact, it took me only 15 minutes to complete this part of the project.

Getting Started - Creating a CAD

Overview:

In this stage, I focused on designing the 3D model and creating the essential components of the belt conveyor. The goal was to establish a complete digital representation that could later be used for mechanical simulations and assembly planning.

What I did:

• Started by modeling the drive pulley, ensuring proper dimensions and clearances.
  
• Built the frame tubes and their supporting structure, paying attention to alignment and assembly constraints.
  
• Designed the mounting brackets to securely connect the components while allowing some adjustability.
  
• Gradually assembled all parts into a single coherent CAD model, checking fits and interactions along the way.
  

Outcome:

After several hours of focused work, I managed to complete the full 3D model. The CAD assembly now provides a solid foundation for the next stages, including motion analysis and mechanical testing.