By today all the holes for the panel mounting parts have been finished. Next I proceed with the internal parts layout arrangement. Once this work finished, by next Monday I will install all the components inside the panel box. I have a bit problem with the original layout since once all the components are put in, I realized the space there is quite limited. As such I have to take out one terminal block and wire harness rail cover plus the RS232 adapter.
Went to Pasar Road on Friday to buy accessories and components for PLC control box. Some of the acessories are anot available which means I have to seek somewhere else such as wire trunking, bigger drill bits, files etc.
The control panel was designed in such a way that it will be placed underneath the conveyor B. As such a holder need to be fabricated for it to be rest there. The reason it is chosen to be placed there is for future layout change. Any layout later on wont affect the external wiring because all parts and wiring are installed on the conveyors themselves.
The front panel is meant for components display and the rear panel is for input output connectors. There is only one AC switch being installed infront of the panel. The rest of the control is done by the PLC itself. The only external switch are START STOP and EMERGENCY where they are fitted in the wired switch box closed to the packaging control panel and operator input mooncake. This is the sketch of how the panel box would looks like.
Anyway, now the task to make holes for components assembly on the control box have been passed to Mr Eluis. Meanwhile a few items must be done to complete the project by middle of this month such as.
1- Stainless Steel Stepper to cross over the conveyor. (Mr Khow & Mr Eluis)
2- Control panel holder.
3- Small mooncake guide attachment.
4- PLC ladder diagram
5- Small mooncake slider attachment
6- 125mm pusher holder.
As promised today, Enviro came and upgrade the conveyor belt from 1 ply white color Halal Belt to 2 ply blue color Halal belt. This time the belt is non glossy, therefore making it less smooth to avoid mooncake sliding whenever conveyor stop. It cost RM180 for 6ft conveyor and RM280 for 12ft conveyor (Total cost RM740).
With this upgrade, hopefully we wont have same problem with the previous belt (sliding, sensor sensitivity). Thorough test will be done soon to ensure no stupid mistake in terms of design or material selection still exist.
Anyway I went to Pudu pasar road to purchase the accessories items for PLC today. I cant find the control panel as electrical installation. Instead I bought an epoxy painted metal casing for racking panel. This is quite good enough as it can still fit the items required inside it.
Today we assembled the S5S6 hardwires control system. Once completed, we tested and founf it OK. This control system is similar to S3S4 except for one relay I use MY4N instead of LY2. The reason is the contact involved is not AC but DC even though I only use two contacts instead of 4 available. The S1S2 work is only for the platform upgrade without big design change. Now I place it on the plywood and the AC connection is not directly to the inverter. Instead I pass it through relay first.
Anyway once all done, we run the full trial. This is the video showing how the trial went through.
Basically it's all OK. However as usual a few upgrade is required, such as :
1- The sachet feeder few switches (RESET, CURT, RUN) should be made available in parallel form where the small switch box can be placed next to packaging machine. This is to ensure that the machine operator don't have to move back and forth just to reset the process once machine failure is happening.
2- The ICTS switches (START/STOP, EMERGENCY SWITCH) should be installed next to packaging as well to avoid delay of restarting the process and to minimize packaging defects.
Based on last week design, today I assemble the circuit to replace the old circuit hardwires. Everything went smoothly, and later on upon testing with the actual conveyor system, it works perfectly. Here is the hardwires new control system looks like.
Based on the assembled circuit it it obvious that I make one minor change of the component, LY2 relay (parallel relay for conveyor B controller) replaced with MY4N. Note that this time I assemble the circuit on the plywood for neatness. I also attached the AC socket together on the plywood to avoid wiring messy around the inverter. The rest is same as the actual design.
Anyway, today I also received the items that I ordered from Omron last week. Now I have all the automation components required. Tomorrow I will assemble another control system for S5S6 sensors. The control system is simillar to S3S4 circuit.
The sensors bracket fabrication for S3S4 and S5S6 also completed by today. 
By tomorrow they gonna complete the aluminum guide as well as upgrading the AC cords wiring as well as installing the plywood base for the relays control system. Mr Yu decided to stop the conveyor cover fabrication as this year he want to place a mobile operator to look after the conveyors all the time. He want to ensure that if accident happened, somebody are ready to clear up the mess. Here is another view of the holder from front side.
SMC pneumatic actuator CXSM15-125-XB11 and all its accessories were ordered last Saturday and should be arriving sometime this week.
Enviro vendor deliver a patch of blue halal conveyor belt (H/2LB 2-374 Halal) for trial late this afternoon. 
Simple test were done, and it is found that this belt produced quite simillar result as the old green PVC. The good news is this one is smoother than that PVC which means better pushing to the packaging conveyor. We will do thorough test by tomorrow.
As during test we found that the mooncakes might hit each other while transfering from slower conveyor to faster one, so we decide to apply the same concept of checking at slower conveyors as the fastest one. Here is the new design.
Meanwhile arrangement have been made with Enviro to change the CB conveyors to 2ply Halal Blue conveyor by Monday next week at RM180 cost. Infact it would cost some more for installation, but they waived it for us.
As for SMC actuator, they promised to quote for 125mm CXS model with valve by this week ASAP.
Next for PLC accessories, request for quotation have been sent to AAA Engineering to supply.
As for the time being, since the cash to buy for conveyor covers is not available yet, nothing much can be done. Perhaps we can use the available time to come up with improve design and project planning as well as testing with the existed old design.
We did some testing using the old hardwires control system on the first two new conveyors. Few problems arised that require further test and upgrade of the design. Here are the problems :
1- The conveyors too shiny that affect sensor sensitivity. Discuss with Enviro vendor to quote and supply a replacement belt that is more sticky and less glossy. She promised to quote by tomorrow a blue halal 2 ply conveyor belt that might cost around RM200 for us to test until the best one is decided.
