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Automation Of Bolt Galvanisation Plant using PLC

Ashutosh Singh1, Debajit Tapadar1, Sitanshu Sekhar Mondal1, Soumyaroop Sengupta1


Department of Electrical Engineering, West Bengal University of Technology, Kolkata, India Email:

Abstract Human necessities are increasing day by day where as the factories are running out of resources. To meet these demands industries need to improve the quality and quantity of their production. One of the reliable and faster methods is by virtue of automation which not only increases the production level but also helps us to maintain space usage. At the same time industries needs to take care of creating an environment friendly working atmosphere and minimum energy consumption. Keeping all the above things in mind one of the important and pivotal industries of any generation, a galvanizing industry has been redesigned. This paper deals with a bolt galvanizing industry designed automatic with the help of PLC. Keywords- PLC, Carousels, Level Detectors, Conveyor Belts, Hotter, Proximity Sensors

to the motors which act as the brain of the crane. High temperature sensor technology applies major breaking points in the control of the system. C. FAULT ANNUNCIATION SYSTEM
Fault can occur in any part of the operation. For any kind of faults in the whole operation hooters and safety lamps are provided for immediate system recovery. The signal plow manner of PLC to the various systems via sensors in the plant is shown in figure 1.



Galvanizing industry has revolutionized and taken a major share in the global market for producing long lasting, high standards rust-free ferrous products. The focus of the paper is mainly on increasing production capacity and plant space management. The entire operation is done in different segments. Brownout is usually avoided by the timing control mechanism. There are various types of sensors and level detectors at critical points that help in controlling the operation. Here only a part of process flow has been designed which are under the following heads: A. CONVEYOR CONTROL SYSTEM In Conveyor control system, the entire operation starts automatically, when a Start Button is pressed. The conveyors end their journey in front of their respective machines for the corresponding output. There are several sensors used in critical areas of the system, which informs the operator either entire system is running normally or any fault occurred in any device. Several pressure sensors are used to employ power saving technology and to avoid unwanted running process. B. CAROUSEL CONTROL SYSTEM It is the most important part in galvanizing process. In Carousel Control System, an operator is required to controls the shafts holding raw material buckets depending on some conditions of movement. This system reduces plant area to a certain level contributing to the environment and also increases production. The logical signals are sent from PLC A.

Figure1:- PLC operating with other sensors




INPUTS:-Start Push Button (PSH), Stop Push Button (STP), Limit sensor for Forming Machine (LIMS), pressure sensor to the conveyor (PRS1, PRS2, PRS3, PRS4), limit switch for each conveyor (CLS1, CLS2, CLS3) OUTPUTS:-CONVEYOR 1A (CONV1), CONVEYOR 2A (CONV2), CONVEYOR 3A (CONV3), CONVEYOR 4A (OUTCONV), FORMING MACHINE (FM). PROCESS DESCRIPTION:When PSH is pressed a memory unit is initiated which acts as the control unit for 1A, 2A, 3A & 4A. The process starts from FM. After straightening of rods in FM a cutter is started on the basis of sensing of LIMS. The raw material falls on 1A. PRS1 senses the incoming material and starts 1A.the journey ends at CLS1. After process operation the output is held on to 2A.PRS2 activates 2A which ends at CLS2. The required mechanism is

978-1-61284-764-1/11/$26.00 2011 IEEE

performed whose output is again mov ved to 3A.PRS3 activates 3A which ends at CLS3.After certain operation ivates 4A which the output is moved to 4A. PRS4 acti moves the material to the next section. Th he whole process is shown in ladder diagram1.

motor stops initiating a time ga ap for the pit operation. With the end of the time gap, th he up motor starts until it reaches LSY. With the pressure sensor s and LSY activated the hoist crane continues the circular c path pausing at respective pits. At the hot galvani izing pit RF is used as the down pit sensor. The system goes on moving as there is opping. The STP switch no initial and final point of sto enables the stopping function at t any certain point. PSH initializes the unloading process just as the beginning of s shown in the adjoining the process. The ladder logic is ladder diagram2. The signal flow w through plc is shown in figure 2.

Ladder1:- Conveyor Control Syst tem



INPUTS:-Start Push Button(PSH),Stop p Push Button (STP),Pressure Sensor(PRS), Limit sen nsor at X(LSX), Limit sensor at Y(LSY),Proximity s sensors at each pit(PES),Down Pit Sensor(DPS), Hot Pit Sensor(HTS). otor (UM), Down OUTPUTS:-Main Motor (MTR), Up Mo Motor (DM), Safety Lamp (SL), Bucket F Filled (BFD) PROCESS DESCRIPTION: In Carousel Control System there are tw wo paths for the movement of crane; one is the vertical path and the other is the circular path. There are two limits switches LSX & nsors govern the LSY in the vertical path. The DPS sen circular movement. These switches are c connected to PLC input terminals. If the hoist is at A and af fter loading when push button is pressed a timer operation is used to indicate ndicated it moves the bucket is filled or not. After BFD is in towards LSY. The up motor continues til ll it reaches LSY. At this point when PRS and LSY are O ON, motor MTR starts towards the first pit. PES sense es the incoming material and stops the forward d motor. An acknowledgement signal is sent to the operator through ps the PES and SL. The acknowledgement signal stop activates the down motor. At the point t DPS, the down

ontrol System Ladder2:- Carousel Co

The whole automation system can be i illustrated by the AUTOCAD diagram mentioned in figure 2 below.



A Computer is as important to the business b world as PLC to the industrial world. The whole logic is developed in ZELIOSOFT software and verified d in GE Fanuc PLC. The system creates a fast, real-time decision making environment. The process is adap ptable to any changes in production capacity or safety requirements. In short integrated automation process pro oduces a reliable quality galvanizing industry. IV. i.

Carousel Mechanism by Aske eland, Lwif J.(Cranston, RI) developed by Playskool.Inc International Journal of Auto omation and Control 2007 Vol. 1, No.2/3 Pages.220 232 Drive Mechanism for use with an overhead shaft of a M (Drummondville, CA) sectional door by Beaudoin, Michel Foucault, Pierre-louis (St-Lambert, CA) Tremblay, Richard (Drummondville, CA) vieres, CA) Frchette,Jonathan (Trois-Riv Multisensor collaboration in n wireless sensor networks for detection of spatially correlated signals, Asis M Network Design and Nasipuri, Kai Li - Int. J. of Mobile Innovation 2006 - Vol. 1, No.3 3/4 pp. 215 22 Moving belt conveyor mechanism by Ward, Christopher J. (Barnby Dunn, Near N Doncaster, GB2) Hughes, Septimus (South Shie elds, GB2)

Figure 2:- Process flow diagram m

ii. iii.



INPUTS: - Up-Down Motor (UDM), U Up-Down Motor Speed Sensor (UDMS) Forward-Reverse Motor (FDM), RMS) Forward-Reverse Speed Sensor Motor (FR OUTPUTS: - Red Light (RLED), Green L Light (GLED). PROCESS DESCRIPTION:Low speed and over speeds are common n faults in motor. When UDMS OR FRMS does not sense RLED will glow indicating faults otherwise GLED will lit up continuously. The logic is designed in lad dder3.



Ladder3: - Fault Annunciation Contro ol