i
AUTOMATIC AUTOMATIC BOTTLE BOTTLE FILLING FILLING WATER WATER SYSTEM SYSTEM USING USING PLC WITH WITH CONVEYOR CONVEYOR MODEL MODEL
A thesis submitted submitted i !u"!i""met !u"!i""met #! the $e%ui$emet !#$ the &'&$d #! the de($ee #! B&)he"#$ #! E(iee$i( *E"e)t$#i)s + Ist$umet&ti# ,
Faculty of Electronics & Instrumentation Engineering Engineering Aarupadai Veedu Institute of Technology ( Vi&-&.& Missi# Ui/e$sit-,
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DECLARATION
0I he$eb- de)"&$ed th&t this thesis tit"ed 1Aut#m&ti) B#tt"e Fi""i( W&te$ S-stem Usi( PLC2 is the $esu"t #! m- #' e!!#$t e3)e4t &s )"e&$")"e&$"- st&ted i $e!e$e)es the s#u$)e #! $e!e$e)e5 $e!e$e)e5
Signature :- …………………………………… ame of Author :- ………………………………!!!!!! D&te 67 ………………………………!!!!!
ii
DECLARATION
0I he$eb- de)"&$ed th&t this thesis tit"ed 1Aut#m&ti) B#tt"e Fi""i( W&te$ S-stem Usi( PLC2 is the $esu"t #! m- #' e!!#$t e3)e4t &s )"e&$")"e&$"- st&ted i $e!e$e)es the s#u$)e #! $e!e$e)e5 $e!e$e)e5
Signature :- …………………………………… ame of Author :- ………………………………!!!!!! D&te 67 ………………………………!!!!!
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To my beloved father, mother, brother and sister
i" ACKNOWLEDGEMENT
Fi$st #! &""8 I '#u"d "i.e t# th&. L#$d 9RISHNA !#$ HIS !i$m h&ds i (uidi( me i the )#u$se #! )#m4"eti( this thesis '$iti(: It is b- HIS ($&)e &d me$)- th&t I &m &b"e t# #bt&i the $ese&$)h # 4"&i( 4$#;e)t 'ithi su)h &s "imited time: Se)#d8 I '#u"d "i.e t# e34$ess m- ($&titude &d th&.s t# m- F&)u"t- Assist&ts8 M$s: M:CHITRA + L:Chit$&8 !#$ his 4$#!essi#&" (uid&)e8 'isd#m8 edu$&)e8 &d/i)es m#ti/&ti# &d e)#u$&(emet du$i( his su4e$/isi# 4e$i#d: Th&. -#u s# mu)h !#$ the isi(hts &d e)#u$&(emet she h&s (i/e t# me: With#ut his 4&tie)e &d /&"u&b"e &ssist&)e8 the 4$#;e)t &d thesis '#u"d #t h&/e bee the s&me &s 4$eseted he$e: Besides th&t8 I '#u"d "i.e t# )#/e- m- th&.s t# m- be"#/ed 4&$ets8 M$: Umesh P$&s&d Si(h &d M$s: P##&m Si(h !#$ the &d/i)e &d (i/e &"" su44#$t t# me i de/e"#4i( this 4$#;e)t: M- !e""#' !$ieds sh#u"d &"s# be $e)#(i
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ABSTRACT
N#'&d&-s8 the &44"i)&ti# #! PLC is 'ide"- .#' &d use i this di(it&" '#$"d PLC2s &44"i)&ti# is #b/i#us"&44"ied &t the idust$i&" se)t#$: N#$m&""-8 the PLC2s th&t h&/e bee used &t the idust$i&" !ie"d is usu&""- t# )#t$#" & me)h&i)&" m#/emet eithe$ #! the m&)hie #$ he&/- m&)hie i #$de$ t# )$e&te & e!!i)iet 4$#du)ti# &d &))u$&te si(&" 4$#)essi(: I this 4$#;e)t8 & dis)ussi# &b#ut PLC &44"i)&ti# 'i"" be e34"&ied i m#$e det&i"s &d s4e)i!ied: Whe$eb-8 & m&)hie th&t used t# 4$e4&$e &ut#m&ti) !i""i( '&te$ it# the b#tt"e is !u""- )#t$#""ed b- the PLC CPM=A8 'hi)h &)ts &s the he&$t #! the s-stem: The s-stem se%ue)e #! #4e$&ti# is desi(ed b- "&dde$ di&($&m &d the 4$#($&mmi( #! this 4$#;e)t b- usi( C>7P$#($&mme$ s#!t'&$e: Ses#$ usu&""- 4"&-s its /it&" 4&$t &s & i4ut si(&" t$&smitte$ !#$ the PLC i this s-stem: Du$i( this 4$#;e)t ses#$ h&s bee used t# dete)t the b#tt"e 4#siti# th&t m#/e &"#( the )#/e-#$ be"t &t the "#' s4eed 'hi"e the m&)hie #4e$&tes: The i4ut si(&" th&t h&s bee set !$#m the ses#$ t# the PLC h&s bei( m&de &s & $e!e$e)e: Si(&" i #$de$ t# dete$mie the #ut4ut si(&" th&t e3&)t"- & s&me 'ith the PLC 4$#($&mmi( "&(u&(e b&sed # the use$ $e%ui$emet: Beside th&t8 the e"e)t$#i)s &d e"e)t$i) de/i)es th&t usu&""- bee )#t$#""ed b- the PLC &$e "i.e & m#t#$8 4um48 ses#$8 )#/e-#$ be"t8 bu<
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TABLE OF CONTENTS
#$A%TE TIT'E %AE TIT'E %AE i )E#'AATI* ii )E)I#ATI* iii A#+*,'E)EET i" A.STA#T " TA.'E *F #*TETS "i 'IST *F TA.'ES i/ 'IST *F FI0ES / 'IST *F A%%E)I1S /ii 2 2
.A#+*0) *F %*3E#T
2!2 Introduction 2 2!2!2 *pen-'oop Systems 4 2!2!4 #lose-'oop Systems 5 2!4 %ro6lem Statement 7 2!5 %ro8ect *68ecti"e 9 2! Scope of %ro8ect 9 2!7 Implementation of %ro8ect ; 2!9 Thesis *utline <
4 2=
'ITEAT0E EVIE,
4!2 2= 4!4 24 4!5 25 4!5!2 2 4!5!4 27 4! 2; 4!7 2< 4!9 2?
$istory of %'# ,hat is %'#> 'adder 'ogic 'adder 'ogic Input 'adder 'ogic *utput %rogramming *peration of %'# Time esponse
5 ET$*)*'*@ 44 5!2 44 5!4 4 5!5 47 5!2!2 47 5!2!4 49 5!2!5 4;
ethodology *"er"ie $o )oes the System ,orB $ardare )esign #on"eyor System otor Infrared Sensor
Vii CHAPTER TITLE
4? !2 4? !4 54 !5 55 !5 57
E'E#TI# )ESI )# Input A# Input elay *utput Transistor *utput
PAGE
7 %*AI )EVE'*%ET 5; 7!2 A Systematic Approach of #ontrol System )esign 5; 7!4 State )iagram = 7!5 Assignment of Inputs and *utputs 2 7! 'adder )iagram 4
6 44 9!2 9!4 9 9!5 ;
7 49 ;!2 ? ;!4 7=
FINAL RESULT
The %rototype The ,iring System The $ardare )esign
CONCLUSION AND RECOMMENDATION
#onclusion Future ecommendation
REFERENCES 51 APPENDIX 53
"iii LIST OF TABLES
TA.'E *! %AE 7!2 2 7!4 2
TIT'E
Assignment of Inputs! Assignment of *utputs!
i/ LIST OF FIGURES
FI! o! %AES 2!2 4 2!4 5 2!5 ; 4!2 24 4!4 2 4!5 27 4! 29 4!7 2; 5!2 45 5!4 4 5!5 47 5! 4; !2 4? !4 5= !5 52 ! 54 !7 55 !9 55 !; 5 !< 57
TIT'E
.locB diagrams of open-loop system .locB diagrams of closed-loop system %ro8ect Flo #hart Typical of %'# A Simple elay #ontroller 'adder 'ogic Inputs 'adder 'ogic *utputs A Simple 'adder 'ogic )iagram )esign of %ro8ect #on"eyor )esign )# otor .asic I recei"eCtransmit *utput for % and %% sensor Internal )# input circuit diagram ,iring of A# input Internal input circuit diagram ,iring of elay *utput Internal elay *utput )iagram ,iring of Transistor for % Type Internal *utput #ircuit )iagram for % Type *utput
7!2 5< 7!4 5? 7!5 = 7! 4 9!2 9!4 9!5 9! 7 9!7 7 9!9 9 9!; 9 9!< 9 9!? ;
A Systematic Approach to %rogramma6le #ontrol )esign Flo #hart State )iagram of the *peration! .locB )iagram of %lant 'adder )iagram The system from side "ie The system from top "ie The system from front "ie The %'# electrical iring system The e/ternal poer supply The con"eyor system The 6uDDer circuit The I sensor circuit The process of the filling ater
1 LIST OF APPENDICES
A%%E)I1 %AE
TIT'E
A 75
)ata Sheet of #%4A
. 9<
#ircuit of I Emitter and )etector
# ;=
)ata Sheet of '54
#$A%TE 2
BACKGROUND OF PROJECT
2!2
Introduction
C#t$#" e(iee$i( h&s e/#"/ed #/e$time: I the 4&st8 hum&s 'e$e the m&i meth#d !#$ )#t$#""i( & s-stem: M#$e $e)et"-8 e"e)t$i)it- h&s bee used !#$ )#t$#" &d e&$"- e"e)t$i)&" )#t$#" '&s b&sed # $e"&-s: These $e"&-s &""#' 4#'e$ t# be s'it)hed # &d #!! 'ith#ut & me)h&i)&" s'it)h: It is )#mm# t# use $e"&- t# m&.e sim4"e "#(i)&" )#t$#" de)isi#s: The de/e"#4met #! "#' )#st )#m4ute$ h&s b$#u(ht the m#st $e)et $e/#"uti#8 the P$#($&mm&b"e L#(i) C#t$#""e$ *PLC,: The &d/et #! the PLC be(& i the ?@s8 &d h&s be)#me the m#st )#mm# )h#i)e !#$ m&u!&)tu$i( )#t$#"s: ?:
PLC h&s bee (&ii( 4#4u"&$it- # the !&)t#$- !"##$ &d 'i"" 4$#b&b"- $em&i 4$ed#mi&t !#$ s#me time t# )#me: M#st #! this be)&use #! the &d/&t&(es67
C#st e!!e)ti/e !#$ )#t$#""i( )#m4"e3 s-stems F"e3ib"e &d )& be $e&44"ied t# )#t$#" #the$ s-stems %ui)."- &d e&si"C#m4ut&ti#&" &bi"ities &""#' m#$e s#4histi)&ted )#t$#" Trouble shooting aids make programminng easier and reduce downtime. Reliaable componnents make these likely to operate for years before failure.
C#t$#" s-stems &$e & ite($&" 4&$t #! m#de$ s#)iet-:It )#sists #! subs-stems &d 4$#)esses &ssemb"ed !#$ the 4u$4#se #! )#t$#""i( the #ut4uts #! the 4$#)esses:The$e &$e m&ume$#us &44"i)&ti#s th&t usi( )#t$#" s-stem &$#ud us: A )#t$#" s-stem 4$#/ides & #ut4ut #$ $es4#se !#$ & (i/e i4ut #$ stimu"us:The $e&s# th&t )#t$#" s-stem '&s bui"t is!#$ 4#'e$ &m4"i!i)&ti#8 $em#te )#t$#"8 )#/eie)e #! i4ut !#$m &d )#m4es&ti# !#$ distu$b&)es:
T#d&- )#t$#" s-stems !id 'ides4$e&d &44"i)&ti# i the (uid&)e8 &/i(&ti#8 &d )#t$#" #! missi"es &d s4&)e)$&!ts8 &s 'e"" &s 4"&es &d shi4 &t se&: The &44"i)&ti#s &"s# th$#u(h#ut the 4$#)ess )#t$#" idust$-8 $e(u"&ti( "i%uid "e/e" t&.s8 )hemi)&" )#)et$&ti#s i /&ts8 &s 'e"" &s thi).ess #! !&b$i)&ted m&te$i&":
4
1
2.2 What i a PLC! A %rogramma6le 'ogic #ontroller %'# is a digital computer used for automation of industrial processes such as control of machinery on factory assem6ly lines! 0nliBe general-purpose computers the %'# is designed for multiple inputs and output arrangements e/tended temperature ranges immunity to electrical noise and resistance to "i6ration and impact! %rograms to control machine operation are typically stored in 6attery-6acBed or non-"olatile memory! A %'# is an e/ample of a real time system since output results must 6e produced in response to input conditions ithin a 6ounded time otherise unintended operation ill result!
A %'# (i!e! %rogramma6le 'ogic #ontrollerH is a de"ice that as in"ented to replace the necessary seuential relay circuits for machine control! The %'# orBs 6y looBing at its inputs and depending upon their state turning onCoff its outputs! The user enters a program usually "ia softare that gi"es the desired results! %'# are used in many Jreal orldK applications! If there is industry present chances are good that there is a plc present! Almost any application that needs some type of electrical control has a need for a %'#!
2.3 Ladder Logic
Ladder logic is the main programming method used for PLC. As mention before, ladder logic has been deeloped to mimic relay logic. The decision to use the relay logic diagrams was strategic one. !y selecting ladder logic as the main programming method, the amount of retraining needed for engineers and trades people was greatly reduce. "#$
odern control systems still include relay 6ut these are rarely used for logic! A relay is a simple de"ice that uses a magnetic field to control a sitch! elay are used to let one poer source close a sitch for another poer source hile Beeping isolated! An e/ample of a relay in a simple control application is shon in Figure4!4! In this system the first relay on the left is used as normally closed and ill allo current to flo until a "oltage is applied to the input A! The second relay is normally open and ill not allo current to flo until the "oltage is applied to the input .! If current is floing through the first to relay then current ill flo though the coil in the third relay and closed the sitch for output #! This circuit ould normally 6e dran in the ladder logic form! This can 6e read logically as # ill 6e on if A is off and . is on! 9G
2.3.1 Ladder Logic Inputs
%'# inputs are easily represented in ladder logic! In Figure 4!5 there are three types of inputs shon! The first to are normally open and normally closed inputs discussed pre"iously! The IIT (Immediate InputH function allos inputs to 6e read after the input scan hile the ladder logic is 6eing scanned! This allos ladder logic to e/amine input "alues more often than once e"ery cycle! (ote: This instruction is not a"aila6le on the #ontrol 'ogic processors 6ut is still a"aila6le on older models!H 9G
2.3.2 Ladder Logic Outputs
In ladder logic there are multiple types of outputs 6ut these are not consistently a"aila6le on all %'#! Some of the outputs ill 6e e/ternally connected to de"ices outside the %'# 6ut it is also possi6le to use internal memory locations in the %'#! Si/ types of outputs are shon in Figure 4!! The first is a normal output hen energiDed the output ill turn on and energiDe an output! The circle ith a diagonal line through is a normally on output! ,hen energiDed the output ill turn off this type of output is not a"aila6le on all %'# types! ,hen initially energiDed the OSR (*ne Shot elayH instruction ill turn on for one scan 6ut then 6e off for all scans after until it is turned off! The L (latchH and U (unlatchH instructions can 6e used to locB outputs on! ,hen an L output is energiDed the output ill turn on indefinitely e"en hen the output coil is reenergiDed! The output can only 6e turned off using a U output! The last instruction is the IOT (Immediate *utputH that ill allo outputs to 6e updated ithout ha"ing to ait for the ladder logic scan to 6e completed! 9G
Figure 4! 'adder 'ogic )iagram
2.4 Programming
%rogramming softare #1-%rogrammer has 6een utiliDed in this pro8ect! #1%rogrammer is a %'# programming tool for the creation testing and maintenance of programs associated ith **Ls #%4A series! It pro"ides facilities for the support of %'# de"ices and address information and for communications ith ** %'#s and their supported netorB types! An e/ample of ladder logic can 6e seen in Figure 4!7! To interpret this diagram imagines that the poer is on the "ertical line on the left hand side e call this the hot rail! *n the right hand side is the neutral rail! In the figure there are to rungs and on each rung there are com6inations of inputs (to "ertical linesH and outputs (circlesH! If the inputs are opened or closed in the right com6ination the poer can flo from the hot rail through the inputs to poer the outputs and finally to the neutral rail! An input can come from a sensor sitch or any other type of sensor! An output ill 6e some de"ice outside the %'# that is
sitched on or off such as lights or motors! In the top rung the contacts are normally open and normally closed! This means if input A is on and input . is off then poer ill flo through the output and acti"ate it! Any other com6ination of input "alues ill result in the output X 6eing off! ;G
Figure 4!7: A Simple 'adder 'ogic )iagram
2.5 Operation of PLC
A %'# orBs 6y continually scanning a program! ,e can thinB of this scan cycle as consisting of 5 important steps! There are typically more than 5 6ut e can focus on the important parts and not orry a6out the others! Typically the others are checBing the system and updating the current internal counter and timer "alues! 7G
%tep 1&CHECK INP! "!#!"&'irst the PLC takes a look at each input to determine if it is on or off. (n other words, is the sensor connected to the first input on) *ow about the second input) *ow about the third... (t records this data into its memory to be used during the ne+t step. %tep &E$EC!E P%O&%#'&-e+t the PLC e+ecutes your program one instruction at a time. aybe your program said that if the first input was on then it should turn on the first output. %ince it already knows which inputs are on/off from the preious step it will be able to decide whether the first output should be turned on based on the state of the first input. (t will store the e+ecution results for use later during the ne+t step. %tep 0&P(#!E O!P! "!#!"&'inally the PLC updates the status of the outputs. (t updates the outputs based on which inputs were on during the first step and the results of e+ecuting your program during the second step. !ased on the e+ample in step it would now turn on the first output because the first input was on and your program said to turn on the first output when this condition is true. After the third step the PLC goes back to step one and repeats the steps continuously. ne scan time is defined as the time it takes to e+ecute the 0 steps listed aboe. 2.) !ime %esponse
The %'# can only see an input turn onCoff hen itLs looBing! In other ords it only looBs at its inputs during the checB input status part of the scan!
(n the diagram, input 1 is not seen until scan . This is because when input 1 turned on, scan 1 had already finished looking at the inputs. (nput is not seen until scan 0. This is also because when the input turned on scan had already finished looking at the inputs. (nput 0 is neer seen. This is because when scan 0 was looking at the inputs, signal 0 was not on yet. (t turns off before scan 2 looks at the inputs. Therefore signal 0 is neer seen by the plc. -ow let3s consider the longest time for an output to actually turn on. Let3s assume that when a switch turns on we need to turn on a load connected to the plc output.
The diagram 6elo shos the longest delay (orst case 6ecause the input is not seen until scan 4H for the output to turn on after the input has turned on!
Pu*se stretc+ function. This function e+tends the length ofthe input signal until the plc looks at the inputs during the ne+tscan.4 i.e. it stretches the duration of the pulse.5
Interrupt function. This function interrupts the scan toprocess a special routine that you hae written. i.e. As soon as the input turns on, regardless of where the scan currently is,the plc immediately stops what its doing and e+ecutes aninterrupt routine. 4A routine can be thought of as a miniprogram outside of the main program.5 After its done e+ecuting the interrupt routine, it goes back to the point it leftoff at and continues on with the normal scan process.
CH#P!E% 3 'E!HO(OLO&,
This chapter will mainly discuss about the methodology of the pro6ect and also the aspect or factors that must be taken into consideration during the deelopment process. All this factors were
ery important to make sure the pro6ect will achiee it ob6ectie. oreoer, this chapter will also discuss about the designation stage on this pro6ect including electronic design, hardware design and material selection.
3.1 Pro-ect Oerie/
In this section it ill discuss an o"erall o"er"ie of Automatically Filling ,ater System 0sing %'# pro8ect! The introduction to system tasB ill also 6riefly e/plain in this chapter! Finally the entire decision maBing ill 6e addressed in this section! .asically softare and hardare design ill 6e used in order to implement this pro8ect! In addition there some methods must 6e e/ecuted to Beep this pro8ect implemented successfully!
3.2 ,- D-& th& S$t&+ W-/0!
Figure 5!2: )esign of %ro8ect
Through this pro8ect the 6ottle ill mo"e on the con"eyor 6elt! The con"eyor ill 6e stopped automatically after the infrared sensor detected the presence of the 6ottle! The controller ill sitch on the pumps hen the con"eyor stops to mo"e! The ater pump ill start to fill into the 6ottle! The filling process ill 6e stopped automatically 6y using the timer and ill 6e turn on and 6uDDer ill sound for fi"e seconds su6seuently! This system ill repeat the process continuously!
3.3 Hard/are (esign
(n the hardware design part, oerall component such as coneyor system, motor, infrared sensor, pump and bu77er circuit will be integrated to form the complete prototype. The hardware components are the backbone of the system. ore detailed information of each section will be discussed in the following sections.
3.3.1 Cone0or "0stem
'igure 0.8 Coneyor 9esign
The dimension of the prototype is appro+imately 1: inch of length and three inch of width. This prototype consist of motor, trek, gear and other electronic circuit. (t presents a continually moing surface that is designed to moe ob6ects from one location to another. Coneyor belt is a long loop of rubber or plastic 4usually combined with steel for strength, 6ust like tire treads5, that is wrapped around a set of motori7ed rollers. A simple coneyor belt will be stretched between two rollers, one drien roll which powers it and one idle roll which is free to spin as the belt moes. 3.3.2 'otor
otor is a small electronic deice that can moe if the power supply connect. (t is a main part to make the coneyor belt moes perfectly. There are many type of 9C otor at market such as gear 9C motor, motor sero and stepper motor but in this pro6ect 9C motor will be used because it can spin 0;<= continuously. oreoer, it is strong enough to moe the trek.
Figure 5!5: )# otor
'igure 0.0 aboe shows the sample of the 9C motor. 9C motor or direct current motor is the most common motor. There are many types of 9C motor likes >&pole motor, seromotor, brushless motor, coreless motor, fi+ magnet motor and many more. 9C motor takes direct current oltages as input and conerts it into a rotational moement.
)# motor 6asically ha"e to ires and can directly poered from a 6attery or other )# poer supply! )# motor also can 6e poer from the dri"er circuit that can regulate the speed and direction of the motor! The usual "oltages of the )# motor use are 9V and 24V! The current rating depends on the maBe of the con"eyor 6uild for and it is usually 6eteen IA and 5A! Varying the "oltage input to the motor ill "aries the speed of motor accordingly! )# motor has a6ility to turn at high re"olution per minutes (%H 6ut has lo torue! The most significant limitation of the )# motor is the lo output torue! The speed can 6e reduced and the torue increase 6y adding gear rain to the output shaft! For the purpose of con"eyor 6elt 6uilding )# motor is the cheapest compare to stepper motor or ser"o motor!
3.3.3 Infrared "ensor
This sensor proides the system with ability to detect the presence of ob6ect position. The theory is the (R emitter emits infrared light. (f an ob6ect presence the signal will be reflected back to the receier. Then, the (R detector implemented will detect the reflected light. Then, the correspondence signal sends to the PLC for being analy7e. "#$
.ased on the measurement of the intensity of the reflected light from the target area such a 6ottle it has a light source sending light to the mo"ing target and a light sensor recei"ing the light! The output signal from the sensor decreases e/ponentially ith the increase of the distance to the measured o68ect! Infrared light-emitting diodes ('E)MsH and photosensiti"e diodes are used in this transducer! The sensor output is in"ersely proportional to the amount of occupation! A multilinB array of light sensiti"e elements and a light-6eam scanning techniue determines and ualifies the shape of the measured o68ect 6y processing data from the elements!
Figure 5! shos the electro optical displacement transducers a N transducer ith mo"ing target 6 N dimension sensorO f = displacement 2 = mo"ing target ith light reflector 4 = light source 5 N light sensor N o68ect to 6e gage!
CH#P!E% 4 ELEC!%IC#L (E"I&N
?lectrical design of the Automatic 'illing @ater %ystem inoles the electrical components used, and the installation of the electrical components on the system. !efore all connection was established all the input and output deices to PLC, the concept on how the input and outputs circuits of PLC must be understood. The wiring of the 9C input, AC input, relay output, and the transistor output is discussed. 4.1 (C Input
Typically, dc input modules are aailable that will work with >, 1, 2, and 2#. the connections of the 9C input modules is either P-P4 sourcing5 or -P-4 sinking5 transistor types deices. 'or a regular switch 4i.e. toggle or pushbutton, etc5, typically no need to worry about whether wire it as -P- or P-P. ost PLCs not allow mi+ -P- and P-P deices on the same modules.
The difference 6eteen the to types is hether the load sitched to ground or positi"e "oltages! An % typeLs sensor has the load sitches to ground hereas a %% de"ice has the load sitches to positi"e "oltage! Figure !2 is shon the output for % and %% sensor!
Figure !2: *utput for % and %% sensor n the -P- sensor, one output is connected to the PLC input and the other output to the power supply ground. (f the sensor is not powered from the same supply as the PLC, both grounds should be connected together. n the P-P sensor, connect one output to positie oltages and the other output to the PLC input. (f the sensor is not powered from the same supply as the PLC, both B3s should be connected together. The common terminal either gets connected to B or ground where it3s connected depends upon the type of sensor used. @hen using -P- sensor this terminal is connected to B, when using a P-P sensor this terminal is connected to <4ground5. A common switch 4i.e. limit switch, pushbutton, toggle etc5 would be connected to the input in similar way. ne side of the switch would be connected directly to B. The other end goes to the PLC input terminal. This assumes the common terminal is connected to < 4ground5. (f the common is connected to B the simply connect one end of the switch to < 4ground5 and the other end to the PLC input terminal.
The photo couplers are used to isolate the %'#s internal circuit from the inputs as shon in Figure !4! This eliminates the chance of any electrical noise
entering the internal circuitry! They orB 6y con"erting the electrical input signal to light and then 6y con"erting the light 6acB to an electrical signal to 6e processed 6y the internal circuit!
Figure !4: Internal )# input circuit diagram
4.2 #C Input
An ac "oltage is non-polariDed means that there is no positi"e and negati"e polarity! Typically ac input modules are a"aila6le that ill orB ith 4 < 22= and 44=V an ac de"ice is connected to input %'# as shon in Figure !5
Figure !5: ,iring of A# input
Commonly the ac hotD wire is connected to the switch while the neutralD goes to the PLC common. The ac ground 40rd wire5 should be connected to the frame ground terminal of the PLC. AC connection is typically color code. (n E% is commonly white 4neutral5, black 4hot5, and green 40rd wire ground when applicable5. utside the E% its commonly coded as brown 4hot5, blue 4neutral5, and green with yellow stripe 40 rd wire ground when applicable5.
A common sitch (i!e! limit sitch push6utton toggle etcH ould 6e connected to the input terminals directly as shon in Figure !! *ne side of the sitch ould 6e connected directly to %'# input! The other end goes to the ac hot ire! This assumes the common terminal is connected to neutral!
Figure !: Internal input circuit diagram
4.3 %e*a0 Output
ne of the most common types of outputs aailable is the relay outputs. A relay can be used with both AC and 9C loads. %ome forms of a load are a solenoid, bu77er, motor, etc. Always check the specifications of the load before connecting it to the PLC output and make sure that the ma+imum current it will consume is within the specifications of the PLC outputs.
Some types of loads are "ery decei"ing! These decei"ing loads are called inducti"e loads! These ha"e a tendency to deli"er a J6acB currentK hen they turn on! This 6acB current is liBe a "oltage spiBe coming through the system! Typically a diode resistor or other snu66ed circuit should 6e used to pre"ent any damage to the relay!
Figure !7: ,iring of elay *utput Figure !7 is a typical method of connecting the outputs to the %'# relays! A# supply or )# supply can 6e used as ell connected to the output! A relay is nonpolariDed and typically it can sitch either A# or )#! $ere the common is connected to one end of the A# poer supply or )# poer supply and the other end of the supply is connected to the load! The other half of the load gets connected to the actual %'# outputs!
The relay is internal to the %'#! Its circuit diagram is shon in Figure !9! ,hen ladder diagram tells the outputs to turn on the %'# ill internally apply a "oltage to the relay coil! This "oltage ill allo the proper contact to close! ,hen the contact close and e/ternal current is alloed to flo through our e/ternal circuit! ,hen the ladder diagram tell the %'# to turn off the output it ill simply remo"e the "oltage from the internal circuit there6y ena6ling the output contact to release the load ill than ha"e an open circuit and ill therefore 6e off!
4.4 !ransistor Output
The ne+t type of outputs is transistor type outputs. Typically a PLC will hae either -P- or P-P type outputs. (t is important to note that a transistor can only switch a dc current. 'or this reason it cannot be used with an ac oltage.
A transistor is a solid-state sitch or an electrical sitch! A small current applied to the transistor 6ase (i!e! inputH and sitch a much larger current through its outputs! The %'# applies a small current to the transistor 6ase and the transistor output JcloseK! ,hen itLs closed the de"ices connected to the %'# output ill 6e turn on!
Figure !;: ,iring of Transistor for % Type Figure !; shos ho to connect the output de"ices to the transistor output for % type transistor! If it ere a %% type the common terminal is connected to VP and V- ould connect to one end of the load!
'igure 2.#8 (nternal utput Circuit 9iagram for -P- Type utput
There is a photo coupler isolating the Jreal orldK from the internal circuit as shon in Figure !
CH#P!E% 5
P%O&%#''IN& (EELOP'EN!
A systematic approach of control system design using programming logic controller is presented in this chapter. As a rule, the layout of the entire of Automatic 'illing @ater %ystem using PLC is designed before implementing programming deelopment process. The machine seFuences of operation will be discussed. -e+t, the assignment of input and outputs are shown in tables. 'inally, the ladder diagram design using CG&Programmer are shown.
5.1 # "0stematic #pproac+ of Contro* "0stem (esign.
In general a control system is a collection of electronic de"ices and euipment hich are in place to ensure the sta6ility accuracy and smooth transition of a process or a manufacturing acti"ity! E"ery single component in a control system plays an important role regardless of siDe! .efore programming the concept of controlling a control system is introduce hich is the systematic approach of control system design using a %'#! The operation procedure of the system approach is shon in Figure 7!2
Figure 7!2: A Systematic Approach to %rogramma6le #ontrol )esign Flo #hart
5.2 Stat& Dia/a+ The general state diagram of the seuences of operation is shon in Figure 7!4 6elo!
Figure 7!4: State )iagram of the *peration
5.3 #ssignment of Inputs and Outputs
After the system seuence of operation is determine all e/ternal input and output de"ices connected to the %'# must 6e determined and assigned the num6er corresponding to the input and output num6er! Ta6le 7!2 and 7!4 shos the assignment of inputs and outputs!
Ta6le 7!2: Assignment of Inputs!
Ta6le 7!4: Assignment of *utputs!
Figure 7!5: .locB )iagram of %lant 5.4 Ladder (iagram
A ladder diagram is produced according to the state diagram of the system and based on the system operation and condition. 'igure >.0 shows the ladder diagram of the system.
The system in the ladder diagram form ill 6e programmed into %'#! *nce the programs ha"e 6een donloaded into %'# it can 6e monitored in the )iagram ,orBspace during e/ecution! Furthermore the #1-programmer pro"ides on-line editing functions during e/ecution! ote that the on-line editing is not possi6le in un mode! All acti"ities occurs can 6e o6ser"ed using the #1-programmer!
Figure 7!: 'adder )iagram
CH#P!E% )
IN#L %E"L!
As mentioned in Chapter 2 and Chapter >, all the system of the desired pro6ect was implemented and the results of the systems illustrated in this Chapter ;. 9uring the operation, all actiities that occur can be obsered by computer using CG&Programmer. The system needs to debug along the way and fine tune if necessary. Test run the system thoroughly until if is safe to be operated. ).1 !+e Protot0pe
The prototype as mainly 6uilt 6y com6ining the mechanical design and the electrical designs! The system reuire three e/ternal )# poer supply for input output de"ices to A# poer supply for supplying pump and %'# and one ?V 6attery for 6uDDer!
The pictures 6elo sho that the prototype of system from different "ie:-
).2 !+e iring "0stem
.efore running the system thoroughly ensure that the input and iring are correctly connected according to the IC* assignment to a"oid any unanted accidents! *nce confirmed the operation of the Automatic Filling ,ater System using %'# can 6e started!
CH#P!E% CONCL"ION #N( %ECO''EN(#!ION
An Automatic Filling ,ater System using %'# has 6een successfully constructed and designed 6y applying all the concept of control system at this pro8ect! The system that is produced can 6e modified to 6e 6etter if some of the electrical de"ices and system are upgraded and impro"ed!
.1 Conc*usion
The theory and concept of the automatic filling ater system is 6ased on the control system! In electrical design the features and functions of the electrical components are reuired to determine the system reuirement! Furthermore the theoretical of the iring system is reuired for connecting the inputs and outputs de"ices to %'#! In programming design understandings of the desired control system and ho to use the 'adder )iagram to translate the machine seuence of operation are the most important parts 6ecause it ha"e direct effect on the system performance! The main aim in this process is to apply %'# to design automatic filling ater system and all o68ecti"es in this pro8ect ere successfully done as planned! Finally the 6asis control system and logic design apply in this pro8ect can 6e used as a references to design other applications of automation system and also can 6e used as a teaching material for the Industrial #ontrol su68ect!
.2 !%E %ECO''EN(#!ION
Actually, a lot of weakness from the pro6ect can be taken as future works so that the improed system will be better in terms of performance. %o that, there are seeral recommendations or suggestions that we can take to increase performance in this pro6ect. The performance of Automatic 'illing @ater %ystem can be increased based on two recommendations which areH The system that is proposed now is using only one sensor that is (R sensor to detect position of bottle. (t will be better if we add more sensors in this system like a flow sensor to detect water flow or use leel sensor to detect water leel. Thus, the system will be more sensitie as there will be more sensing points
!esides using PLC as controller, the other controller can be used in this future work is like icrocontroller. *oweer, many factors must be considered like cost, practically and others.
%EE%ENCE"
"1$ %iemens. I Basic Of PLCs’ %T?P <<< series, %iemens Technical ?ducation Program. "$ "$ -orm -orman an %. -ice -ice ICon IContr trol ol System Engineering 3. 3. Third ?dition. ?dition. Californi Californiaa %tate %tate Polytech Polytechnic nic Eniersity Pomona. John @iley K %on, (nc, << "0$ Colin 9. %impson I Programmable Programmable Logic Controllers Controllers Regents3 Regents3 Prentice *all. "2$ -oel . orris IControl Engineering 3 c RA@&*(LL !ook Company 4EM5 Limited. ">$ Lug, J. N. %., @alker, . @., and Paul, R. P. 41:#
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