Project On PLC For Color Mixer Conveyor

COLOUR MIXER CONVEYOR 1
INTRODUCTION TO MECHATRONICS
Mechatronics is a branch of engineering that deals with the study and design of the
products whose function relies an interdisciplinary branches of engineering namely –
mechanical, electrical, electronics and control system.
Control
systems
Mechanical Electronics
Mechatronics
systems systems
Computer
systems
Mechatronics systems : The integration of microprocessor control system,

electrical system and mechanical system is termed as Mechatronics system.
Mechatronics system includes :
 Measurement and actuation module.
 Communication module.
 Central processing unit (CPU).
 Output signal conditioning module.
 Feedback module.
GOVERNMENT POLYTECHNIC CHANNAPATNA DEPARTMENT OF MECHANICAL ENGINEERING

IMPORTANCE OF MECHATRONICS
There have been rapid changes and improvements in the fields of electronics, computer
and control systems over the last years. As a result of this, computer controlled systems
have been in increase in almost every field. The number of only mechanically operating
systems is very few. The applications of artificial intelligence techniques have been put
into use in design, production and maintenance. Therefore, the design, production and
maintenance of advanced products are no longer a single subject. It has become a must to
use mechanics, electrics and electronics, hydraulics and pneumatic and computer
technologies together. This made Mechatronics emerge as a new discipline. What
Mechatronics covers ranges from home technologies to advanced medical devices and
from computer controlled benches to robots.

The application fields of Mechatronics can be illustrated as

follows:
 Control Systems (position, level, pressure and heat control system)

 Robots (transport and welding robots)
 Industrial Automation (barcode systems and production belts)
 Building Automation (security systems, automatic air conditioning and automatic
door systems)
 Home appliances (washing machines and dish washers)
 Automotive (air bag, antilock braking system)
 Defense Industry (mine detection robots, automatically guided vehicles)
 Medical Applications (magnetic resonance, arthroscopic devices, ultrasonic
probes etc.)
 Aeronautical Engineering (automatic pilots, unmanned aerial vehicles)
 Image and Sound Processing (automatic focusing devices, sound-operated
devices)
 Production (Computerized Numerical Control -CNC, Numerical Control -NC)
 Laser optical systems (barcode)
 Intelligent measuring devices (calibration devices, testing and measuring sensors.
Advantages of Mechatronics.
1) Versatility
Having touch both Mechanical and Electrical, it opens you to a wide field of industries
that you can enter. You can do hands on mechanical work, wiring and programming, key
core skills that would be highly appreciated and especially since you are good at them
2) Robotics & Automation Specialty
Mechatronics are dedicated to the study and learning of Robotics and Automation which
is definitely going to be key growth in the upcoming 2 decades. You are the prime person
that manufacturers and such companies will need and hire you.

3) Growth Potential
Mechatronics is still a relatively small group compared to other fields despite how
important we are in manufacturing and automation. Do it right and you can have a very
good future.
4) Simplified mechanical design.
5) Rapid machine setup.
6) Cost-effectiveness.
7) Rapid development trials.
8) Possibilities for adaptation during commissioning.
9) Optimized performance, productivity, reliability.

INTRODUCTION TO PROGRAMMABLE LOGIC CONTROLLER
A programmable logic controller (PLC), or programmable controller is an

industrial digital computer which has been adapted for the control of manufacturing
processes, such as assembly lines, or robotic devices, or any activity that requires high
reliability control and ease of programming and process fault diagnosis.
Need for PLC.
1. Hard wired panels were time consuming to wire, debug and change.
2. Easy to modify input and output devices.
3. Easily programmed and maintained.
4. Be able to function in industrial faculty efficiently.
5. It should be programmable, reusable, and reliable.
6. It should be in a solid state and no moving parts

TECHNICAL STUDY OF PLC

PLC Operation Steps:
This type of machine uses four steps to operate and control the associated machine.
These work in a repeating loop to keep the right level of control. All machines use the
same loop, starting with the input scan and ending with housekeeping.
Step Process
Input Scan Detects input device state
Connects to PLC
Program Scan Carries out program logic made by user
Output Scan De-energizes or energizes output devices
Connects to PLC
Housekeeping Communicates with internal diagnostic
Communicates with programming terminals
All four steps are straightforward and allow for seamless control operation. How long
each step takes depends on the machine a person is using. However, all PLC machines
work significantly faster than manual controls.
Program Scan
When a PLC executes a program, it must know in real time when external devices
controlling a process are changing. During each operating cycle, the processor reads all
the inputs, takes these values, and energizes or de-energizes the outputs according to the
user program. This process is known as a program scan cycle. Figure 2.2 illustrates a
single PLC operating cycle consisting of the input scan, program scan, output scan.

Special features of PLC :
1. Programming in PLC is easier than wiring the physical components.

2. The PLC can be reprogrammed using user – friendly programming software.
3. Installation and maintenance of PLCs is easier.
4. PLCs take up much less space.
5. The PLC can be connected to distributed plant automation system, supervised and
monitored.
6. PLCs are armored for severe conditions (such as dust, moisture, heat, cold), and
have the facility for extensive input/output (I/O) arrangements.
7. PLCs operate electric motors, pneumatic or hydraulic cylinders,
magnetic relays, solenoids, or analog outputs.
8. PLC may have external I/O modules attached to a computer network that plugs
into the PLC.

Advantages of PLC.
1. Rugged and designed to withstand vibrations, temperature, humidity, and noise.

2. Have interfacing for inputs and outputs already inside the controller.
3. PLCs are easily programmed and have an easily understood programming language.
4. Troubleshooting is Easier and Faster..
5. Easy to develop Programs by offline simulation
6.Less amount of Space Needed
7. Less Maintenance
8.Easy to Monitor Inputs and Outputs by HMI devices....and from PC's
ARCHITECTURE OF PLC
Internal Architecture

Figure shows the basic internal architecture of a PLC. It consists of a central processing
unit (CPU) containing the system microprocessor, memory, and input/output circuitry.
The CPU controls and processes all the operations within the PLC. It is supplied with a
clock that has a frequency of typically between 1 and 8 MHz. This frequency determines
the operating speed of the PLC and provides the timing and synchronization for all
elements in the system. The information within the PLC is carried by means of digital
signals. The internal paths along which digital signals flow are called buses. In the
physical sense, a bus is just a number of conductors along which electrical signals can
flow. It might be tracks on a printed circuit board or wires in a ribbon cable. The CPU
uses the data bus for sending data between the constituent elements, the address bus to
send the addresses of locations for accessing stored data, and the control bus for signals
relating to internal control actions. The system bus is used for communications between
the input/output ports and the input/output unit.
The CPU:
The internal structure of the CPU depends on the microprocessor concerned. In general,
CPUs have the following:
An arithmetic and logic unit (ALU) that is responsible for data manipulation and carrying
out arithmetic operations of addition and subtraction and logic operations of AND, OR,
NOT, and EXCLUSIVE-OR.
Memory, termed registers, located within the microprocessor and used to store
information involved in program execution.
A control unit that is used to control the timing • of operations.
The Buses:
The buses are the paths used for communication within the PLC. The information is
transmitted in binary form, that is, as a group of bits, with a bit being a binary digit of 1
or 0, indicating on/off states. The term word is used for the group of bits constituting
some information.
Thus an 8-bit word might be the binary number 00100110. Each of the bits is
communicated simultaneously along its own parallel wire. The system has four buses:

The data bus carries the data used in the processing done by the CPU. A microprocessor
termed as being 8-bit has an internal data bus that can handle 8-bit numbers. It can thus
perform operations between 8-bit numbers and deliver results as 8-bit values. The address
bus is used to carry the addresses of memory locations. So that each word can be located
in memory, every memory location is given a unique address. Just like houses in a town
are each given a distinct address so that they can be located, so each word location is
given an address so that data stored at a particular location can be accessed by the CPU,
either to read data located there or put, that is, write, data there. It is the address bus that
carries the information indicating which address is to be accessed. If the address bus
consists of eight lines, the number of 8-bit words, and hence number of distinct
addresses, is 28 ¼ 256. With 16 address lines, 65,536 addresses are possible.
The control bus carries the signals used by the CPU for control, such as to inform
memory devices whether they are to receive data from an input or output data and to
carry timing signals used to synchronize actions. The system bus is used for
communications between the input/output ports and the input/ output unit.
Memory:
To operate the PLC system there is a need for it to access the data to be processed and
instructions, that is, the program, which informs it how the data is to be processed. Both
are stored in the PLC memory for access during processing. There are several memory
elements in a PLC system:
System read-only-memory (ROM) gives permanent storage for the operating system and
fixed data used by the CPU.
Random-access memory (RAM) is used for the user’s program. Random-access memory
(RAM) is used for data. This is where information is stored on the status of input and
output devices and the values of timers and counters and other internal devices.
The data RAM is sometimes referred to as a data table or register table. Part of this
memory, that is, a block of addresses, will be set aside for input and output addresses and
the states of those inputs and outputs. Part will be set aside for preset data and part for
storing counter values, timer values, and the like.

Possibly, as a bolt-on extra module, erasable and programmable read-only-memory

(EPROM) is used to store programs permanently.
The PLC processor: It stores the control program and data in its memory. Reads the
status of connected input devices. Executes the control program. Commands connected
outputs to change state based on program execution For example: Turn a light on, start a
fan, adjust a speed, or temperature and Comes in various physical forms.
I/O Modules: They Physically connect to field devices. Input modules convert electrical
signals coming in from input field devices such as pushbuttons, to electrical signals that
the PLC can understand. Output modules take information coming from the PLC and
convert it to electrical signals the output field devices can understand, such as a motor
starter, or a hydraulic solenoid valve. I/O comes in various forms.
A module in PLC.
Programmable Logic Controllers (PLCs) are computers designed to automate

electromechanical processes. They are used in a wide range of applications including
assembly lines, food processing, transportation, injection molding and water treatment.
Interface Module
Interface Modules are small terminals most often used to activate adjacent systems.

User Interface:
PLCs may need to interact with people for the purpose of configuration, alarm reporting
or everyday control. A Human-Machine Interface (HMI) is employed for this purpose.
HMI's are also referred to as MMI's (Man Machine Interface) and GUI (Graphical User
Interface).A simple system may use buttons and lights to interact with the user. Text
displays are available as well as graphical touch screens. Most modern PLCs can
communicate over a network to some other system, such as a computer running a
SCADA (Supervisory Control And Data Acquisition) system or web browser.
Selection criteria of PLC:

* System (task) requirements.
* Application requirements.
* What input/output capacity is required
* What type of inputs/outputs are required
* What size of memory is required
* What speed is required of the CPU
* Electrical requirements.
* Speed of operation.
* Communication requirements.
* Software.
* Operator interface.
* Physical environments.
System requirements:
* The starting point in determining any solution must be to understand what is to be
achieved.
* The program design starts with breaking down the task into a number of simple
understandable elements, each of which can be easily
described.
Application requirements:
* Input and output device requirements. After determining the operation of the system,
the next step is to determine what input and output devices the system requires.

* List the function required and identify a specific type of device.

* The need for special operations in addition to discrete (On/Off) logic.
* List the advanced functions required beside simple discrete logic.
Electrical Requirements:
The electrical requirements for inputs, outputs, and system power; When determining the
electrical requirements of a system, consider three items:
 Incoming power (power for the control system);

 Input device voltage; and
 Output voltage and current.
Speed of Operation:
How fast the control system must operate (speed of operation).
When determining speed of operation, consider these points:
How fast does the process occur or machine operate
Are there “time critical” operations or events that must be detected
In what time frame must the fastest action occur (input device detection to output device
activation)
Does the control system need to count pulses from an encoder or flow-meter and respond
quickly
Communication:
If the application requires sharing data outside the process, i.e. communication.
Communication involves sharing application data or status with another electronic
device, such as a computer or a monitor in an operator’s station. Communication can take
place locally through a twisted-pair wire, or remotely via telephone or radio modem.
Operator Interface:
If the system needs operator control or interaction. In order to convey information about
machine or process status, or to allow an operator to input data,
many applications require operator interfaces. Traditional operator interfaces include

pushbuttons, pilot lights and LED numeric display. Electronic operator interface devices

display messages about machine status in descriptive text, display part count and track
alarms. Also, they can be used for data input.
Physical Environment:
The physical environment in which the control system will be located. Consider the
environment where the control system will be located. In harsh environments, house the
control system in an appropriate IP-rated enclosure. Remember to consider accessibility
for maintenance, troubleshooting or reprogramming
Programming Languages:
A program loaded into PLC systems in machine code, a sequence of binary code numbers
to represent the program instructions. Assembly language based on the use of mnemonics
can be used, and a computer program called an assembler is used to translate the
mnemonics into machine code.
High level Languages (C, BASIC, etc.) can be used.
Programming Devices
1. programming console
2. Hand programmer
3. computer system
PLC Languages
The following is a list of programming languages specified by this standard:

 Ladder diagram (LD)
 Sequential Function Charts (SFC)
 Function Block Diagram (FBD)
 Structured Text (ST)
 Instruction List (IL)
One of the primary benefits of the standard is that it allows multiple languages to be used
within the same programmable controller. This allows the program developer to select
the language best suited to each particular task.

Ladder Logic:
Ladder logic is the main programming method used for PLC's. As mentioned before,
ladder logic has been developed to mimic relay logic. The decision to use the relay logic
diagrams was a strategic one.
By selecting ladder logic as the main programming method, the amount of retraining
needed for engineers and trades people was greatly reduced.
The first PLC was programmed with a technique that was based on relay logic wiring
schematics. This eliminated the need to teach the electricians, technicians and engineers
how to program - so this programming method has stuck and it is the most common
technique for programming in today's PLC.
Mnemonic Instruction
There are other methods to program PLCs. One of the earliest techniques involved
mnemonic instructions. These instructions can be derived directly from the ladder logic
diagrams and entered into the PLC through a simple programming terminal.
Sequential Function Charts (SFC)
SFC have been developed to accommodate the programming of more advanced systems.
These are similar to flowcharts, but much more powerful. This method is much different
from flowcharts because it does not have to follow a single path through the flowchart.
Structured Text (ST)
Programming has been developed as a more modern programming language. It is quite

similar to languages such as BASIC and Pascal. Structured Text (ST) is a high level
textual language that is a Pascal like language. It is very flexible and intuitive for writing
control algorithms.
Function Block Diagram (FBD)
FBD is another graphical programming language. The main concept is the data flow that
start from inputs and passes in block(s) and generate the output.

INTRODUCTION TO LADDER LOGIC
LADDER LOGIC
Ladder Logic, or Ladder Diagrams is the most common programming language used to program a PLC.
Ladder logic was one of the first programming approaches used in PLCs because it
borrowed heavily from the Relay Diagrams that plant electricians already knew. The symbols used
in Relay Ladder Logic consist of a power rail to the left, a second power rail to the right,
and individual circuits that connect the left power rail to the right. The logic
of each circuit (or rung) is solved from left to right. The symbols of these diagrams
look like a ladder - with two side rails and circuits that resemble rungs on a ladder. The picture
above has a single circuit or "rung" of ladder.
• If Input1 is ON (or true) - power (logic) completes the circuit from the left
rail to the right rail - andOutput1 turns ON (or true).
• If Output1 is OFF (or false) - then the circuit is not completed and logic
does not flow to the right – and Output 1 is OFF. There are many logic symbols
CONTACTS AND COILS

With just the Normally Open Contact and Normally Open Coil - a surprising array of
basic logical conditions can be represented.
Normally Open Contact.
Normally Open Coil

This can be used to represent any discrete output from the control logic .When "solved" if the logic
to the left of the coil is TRUE, the referenced output is ON (logical 1).

Below figure shows an example of a single rung ladder.
TIMERS AND COUNTERS
Many times we will want to take action in a

control program based on more than the states of
discrete inputs and outputs. Sometimes, we will want to
turn something on after a delay, or count the number
of times a switch is hit. To do these simple tasks, we will need
Timers & Counters.
Simple Timers (TIM)

A timer is simply a control block that takes an input and changes an output
based on time. There are two basic timer types we will deal with
initially (there are other advanced timers, but we will start with the
basics first) - On-Delay Timer and the Off-Delay Timer.
On-Delay Timer
This timer takes an input, waits a specific amount of time, then turns ON an
output (or allows logic to flow after the delay).

Off-Delay Timer
this timer takes turns ON an output (or allows logic to flow) and keeps that output ON
until the set amount of time has passed, then turns it OFF (hence off-delay)
Simple Counter (CNT)

A counter simply counts the number of events that occur on an input. There are two basic
types of counters- Up counter and a Down counter.
Up Counter
As its name implies, whenever a triggering event occurs, an up counter
increments the counter.
Down Counter
Whenever a triggering event occurs, a down counter decrements the counter
Ladder programs
Ladder programs process inputs at the beginning of a scan and outputs at the end of a
scan, as illustrated in. For each rung executed, the PLC processor will perform the
following steps: The first step is to update the input image table by sensing the voltage of
the input terminals. Based on the absence or presence of a voltage, a 0 or a 1 is stored
into the memory bit location designated for a particular input terminal. The second step is
to solve the ladder logic in order to determine logical continuity. The processor scans the
ladder program and evaluates the logical continuity of each rung by referring to the input
image table to see if the input conditions are met. If the conditions controlling an output
are met, the processor immediately writes a 1 in its memory location, indicating that the
output will be turned ON; conversely, if the conditions are not met a 0 indicating that the
device will be turned OFF is written into its memory location.
And the final step of the scan process is to update the actual states of the output devices
by transferring the output table results to the output module, thereby switching the
connected output devices ON (1) or OFF (0).

INTRODUCTION TO ABB AC31GRAF

PLC SOFTWARE
USER MANUAL FOR ABB AC31GRAF PLC:

Install the ABB software from the CD. After the completion of installation go for Start
menu on the desktop and select on ABB AC31GRAF option as shown and follow the
given steps
1. Project Management Window is opened
2. Click on New button for creating new project

3. Enter the name for the project in the name text box, select the language from the
language option. Select Quick LD (Ladder diagram) & click on OK button.
4. Programming window is opened as shown below.
Considering a simple example, click on F2 key button for inserting Contact on Left.
Rung instructions are explained later.

Double click on the NC contact for entering the input address
Click on the button to select the address.
Select 162.00 for input & O62.00 for output.
5. For verifying the code go for FileVerify option, verify window is seen,
click on verify and Build.

6. Go for Options and Link Configuration
Select the COM port name from the options listed, click on OK.
7. PLC Communication is to be done, go for FilePLC Communication

On click of PLC Communication option, control panel window is opened as shown

below.
Click on Download option send program
click on yes
Click on yes, It asks for updating the EPROM, click on yes
finally EPROM Updated window is seen

8. Check for the desired output through the PLC Interface.
Initially keep the PLC kit in Program mode (off), after downloading the program change
the PLC to Run Mode to verify the output on PLC Panel.
As discussed above quick LD language is selected to build ladder programs as per the
given applications.
The LD Language enables the graphic representation of Boolean expressions. Boolean

AND, OR, NOT, operators are explicitly represented by the diagram topology. Boolean
input variables are attached to graphic coils. The AC31GRAF Quick LD editor provides
diagram entering using either keyboard or mouse. Elements are automatically linked and
arranged on rungs by the Quick LD editor. No connection is drawn manually by the user.
The Quick LD Editor also arranges rungs in the diagram so that the space filled by the
diagram is always optimized.

A Contact modifies the Boolean data flow, according to the state of a Boolean variable.
The name of the variable is displayed upon the contact symbol . The following types of
contacts are supported by AC31GRAF Quick LD Editor.
A Coil represents an action. The rung state is used to force a Boolean variable. The name
of the other variable is displayed upon the coil symbol. The following types of coils are
supported by AC31GRAF.
A block in an LD Diagram can represent a function, a function block, a sub programmer

or an operator. Its first input and output parameters are always connected to rung. Other
inputs and output parameters are literally written outside of the block rectangle.

A jump symbol always refers to a rung label, id. The name of a rung defined somewhere
in the same LD diagram. It is placed at the end of a rung. When the rung state is true, the
execution of the diagram directly jumps to this target rung. Note that backward jumps are
dangerous as they may lead to a blocking of the PLC Loop in some cases.
On Some operators, functions or function blocks , the first input does not have Boolean
data type. As the first input must always be connected to the rung, another input is
automatically inserted at the first position, called ‘EN’. The block is executed only if the
EN input is TRUE. Below is the example of a comparison Operator, and the equivalent
expression.
On some operators, functions or function blocks , the first output does not have Boolean
data type. As the first output must always be connected to the rung, another output is
automatically inserted at the first position called ‘ENO’. The ENO output always takes
the same state as the first input of the block. On some cases , both EN and ENO are

required. Below is an example with an arithmetic operator, and the equivalent code
expressed in pseudo language.
This does not allow to continue a rung (insert other contacts or coils) on the right of a
coil. If several outputs have to be made on the same rung, the corresponding coils must
be drawn in parallel.
The editing grid
The LD diagram is entered in a logical matrix. Each cell of the matrix may contain up to
one LD symbol. Use the arrows of the keyboard, or click on a cell to move the current
selection. The selected cell is marked in
reverse. For some cut/copy/paste operations, it is possible to select several cells. To do

that with the mouse, just drag the mouse cursor in the diagram. With keyboard, use arrow
keys with SHIFT key pressed.
Starting a new rung
To add a new rung to a diagram, move the selection after the last existing rung and insert
a contact (hit F2 or press the corresponding button in the LD toolbar). A new rung with
one contact and one coil is created.
Entering the rung comment
Each rung may be documented with up to two lines of text. To enter a rung comment
text, move the selection on the cell upon the rung and hit ENTER key, or double click on
this cell with the mouse:

Entering the rung label
Each rung may be identified by a name. This name can be used as a target label for jump
operations. To enter or change the label of a rung, move the selection on rung head and
hit ENTER key, or double click on this cell with the mouse:
The AC31GRAF Quick LD editor keeps the memory of the rung labels you already
entered, whether it has been specified for a rung name or a jump operation. The
"Jump/Label"' dialog box gives you the possibility either to enter a new label, or to select
an existing one.
If you enter a new name, it will automatically be added to the list. The "Remove" button
is used to remove the selected name from the list. It does not remove the label on the rung
you selected in the diagram. To do this, just press OK when the edit box is empty.
Inserting symbols on a rung
The insertion of symbols (contacts, coils, blocks...) on an existing rung is always made
according to the current selection. You have to select a valid cell position within the rung
and hit one of the following function keys to insert:

F2 a contact before the selected symbol (on the left)
F3 a contact after the selected symbol (on the right)
F4 a contact in parallel with the selected symbol
F6 a block before the selected symbol (on the left)
F7 a block after the selected symbol (on the right)
F8 a block in parallel with the selected symbol
The following commands are valid when the selection is on the rung output (coil):
F5 add a coil in parallel with the selected one
F9 add a "Jump" symbol in parallel with the selected one
Shift + F9 add a "Return" symbol in parallel with the selected one
For parallel insertion (F4/F8), if several contacts of a rung are selected together, the
symbol is inserted in parallel with the group of selected elements. Below is an example:
To insert symbols in the diagram, you can also use the commands of the "Insert" menu.
With the mouse, you can click on the LD toolbar, on the type of symbol you want to
insert:
Entering symbols
To associate a variable symbol to a contact or a coil, select it and hit ENTER. With the
mouse, double click on the contact or coil. A variable selection box appears. Refer to

chapter "More about program editors" in this document for further information about how
to use this box. To associate a function, function block or operator to a block, hit ENTER
when the selection is on the inside its rectangle. To associate a variable symbol to an
input or output block parameter the selection must be on the corresponding location,
outside the rectangle of the block.
Dialog boxes including variable or block selection lists are normally used for text input.
If the "Manual keyboard input" mode is checked in the "Options" menu, variable symbols
and block names are entered directly in a single text edit box. Enter new text and hit
"Enter" key to validate it, or hit "Esc" key to exit modification and close the text edit box.
The text edit box used in "Manual keyboard input" mode cannot be closed with the
mouse. For a variable, if the symbol does not exist, the variables list appears once the
"Enter" key is hit.
Changing the type of contacts and coils
The "Edit / Change coil/contact type" changes the type of the selected contact or coil. A
contact may be direct, negated, with positive or negative edge detection. A coil may be
direct, negated, set or reset, with positive or negative edge detection. Hitting the SPACE
bar has the same effect.
Inserting a rung in a diagram
The "Edit / Insert rung" command inserts a new rung in the diagram, before the selected
one. The rung is initiated with one contact and one coil.
Correcting a diagram
The DEL key can be used to remove the selected elements. It is not possible to remove a
coils, a jump or return symbol when it is the only output of a rung. Use "Edit / Undo"
command to restore elements after a DEL command. The DEL command can also be

applied to a group of elements selected in the diagram. The DEL command can be used
when selection is on the rung comment text to reset it. The DEL command, used when
the selection is on the rung head, remove the entire rung.
Copying symbols
The "Cut", "Copy", "Paste" commands of the "Edit" menu are used to move or copy
selected elements. These commands do not act on rung comments. The "Edit / Paste
special" command gives you the choice to
insert the pasted elements:
· before the selected element (on the left)
· after the selected element (on the right)
· in parallel with the selected element
Verifying (compiling) the program
The "File / Verify" command runs the AC31GRAF code generator to verify the
programming syntax of the currently edited program. In case of SFC language, both level
1 and 2 are checked. When syntax verification is complete, the code generator window
must be closed to continue work on the program. If there is only one program in the
application (the edited one) the application code is generated if no syntax error is
detected.

INTRODUCTION TO
COLOUR MIXER CONVEYOR

SYSTEM

INTRODUCTION
Colour mixer conveyor system:
This simple application is used for a conveyor system which is performed using the
ladder diagrams and instruction list programmed using quick LD language in ABB AC
31GRAF software.

Components with technical specifications:
PLC ABB AC31GRAF

Actual plant I/O:
Inputs:-8no’s
Outputs:-6no’s
Conveyer Belt
Conveyer timing pulley 2no’s,50mm Dia ,balance spec
Timing relay 2ft.circuilar
Proximity sensor 3 no’s
Solenoid valve 3no’s 24v DC
Motor 60RPM
Base plate 3mm thickness, MS Powder coated
OPERATING PRINCIPLES FOR INDUCTIVE PROXIMITY

SENSORS
Inductive proximity sensors are used for non-contact detection of metallic objects. Their
operating principle is based on a coil and oscillator that creates an electromagnetic field
in the close surroundings of the sensing surface. The presence of a metallic object
(actuator) in the operating area causes a dampening of the oscillation amplitude. The rise
or fall of such oscillation is identified by a threshold circuit that changes the output of the
sensor. The operating distance of the sensor depends on the actuator's shape and size and
is strictly linked to the nature of the material (Table 1).
Table 1. Sensitivity when different metals
are present. Sn = operating distance.

Fe37 (Iron) 1 x Sn
Stainless steel 0.9 x Sn
Brass - Bronze 0.5 x Sn
Aluminum 0.4 x Sn
Copper 0.4 x Sn

Operation:
1. A PLC trainer kit is used to start and stop the servo motors of the conveyor belt
which carries a steel bottle over the conveyor belt.
2. A proximity switch located on the cover detects the position of the bottle.
3. The proximity switch sends signals to a solenoid operated valve which allows the
flow of fluid from the top loaded container into the steel bottle.
4. The rate of flow of fluid is already programmed in ladder software (ex: say for 10
seconds) and hence this permits the required quantity of fluid into the steel bottle
from the first top loaded container.
5. Depending upon the quantity of collection of fluid it is able to modify the time
taken by the solenoid valve to permit the flow of fluid.
6. The same steps are to be followed for collection of fluid from the remaining two
containers.
Ladder diagram:

Connections from PLC kit to colour mixer conveyor model:
PLC KIT CONVEYOR MODEL
Conclusion:
PLC’s are well adopted to a range of automation task. These are typically useful in
industrial processes especially in manufacturing where the cost of developing and
maintaining the automation system is high relative to the total cost of automation. In
mass production industries where a large quantity of products are to be produced which
cannot be achieved through conventional means but perhaps can be fulfilled by a vast
well adopted range of automation which can be gained through PLC. The above
discussed model which is controlled by a PLC finds its applications in industries like
beverage, automotive packaging, food production etc..because of the following
capabilities like consistency, ease of work, accuracy, reduced efforts, just in time
manufacturing, shortening the manufacturing lead time etc. The above miniature model
can be made in advanced manner for the practical applications in mass production
industries..

BIBILOGRAPHY
MECHATRONICS BOOK BY – BOLTEN
https://en.wikipedia.org/wiki/Programmable_logic_controller
https://www.engineersgarage.com/articles/plc-programmable-logic-controller
http://new.abb.com/plc.
http:/www.google.com.

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COLOUR MIXER CONVEYOR 1

Mechatronics systems : The integration of microprocessor control system,

Mechatronics system includes :

 Measurement and actuation module.

 Central processing unit (CPU).

 Output signal conditioning module.

GOVERNMENT POLYTECHNIC CHANNAPATNA DEPARTMENT OF MECHANICAL ENGINEERING

GOVERNMENT POLYTECHNIC CHANNAPATNA DEPARTMENT OF MECHANICAL ENGINEERING

The application fields of Mechatronics can be illustrated as

 Control Systems (position, level, pressure and heat control system)

2) Robotics & Automation Specialty

GOVERNMENT POLYTECHNIC CHANNAPATNA DEPARTMENT OF MECHANICAL ENGINEERING

4) Simplified mechanical design.

5) Rapid machine setup.

7) Rapid development trials.

8) Possibilities for adaptation during commissioning.

9) Optimized performance, productivity, reliability.

GOVERNMENT POLYTECHNIC CHANNAPATNA DEPARTMENT OF MECHANICAL ENGINEERING

INTRODUCTION TO PROGRAMMABLE LOGIC CONTROLLER

A programmable logic controller (PLC), or programmable controller is an

Need for PLC.

GOVERNMENT POLYTECHNIC CHANNAPATNA DEPARTMENT OF MECHANICAL ENGINEERING

TECHNICAL STUDY OF PLC

Input Scan Detects input device state

Program Scan Carries out program logic made by user

Output Scan De-energizes or energizes output devices

Housekeeping Communicates with internal diagnostic

Communicates with programming terminals

GOVERNMENT POLYTECHNIC CHANNAPATNA DEPARTMENT OF MECHANICAL ENGINEERING

Special features of PLC :

1. Programming in PLC is easier than wiring the physical components.

GOVERNMENT POLYTECHNIC CHANNAPATNA DEPARTMENT OF MECHANICAL ENGINEERING

1. Rugged and designed to withstand vibrations, temperature, humidity, and noise.

GOVERNMENT POLYTECHNIC CHANNAPATNA DEPARTMENT OF MECHANICAL ENGINEERING

A control unit that is used to control the timing • of operations.

GOVERNMENT POLYTECHNIC CHANNAPATNA DEPARTMENT OF MECHANICAL ENGINEERING

GOVERNMENT POLYTECHNIC CHANNAPATNA DEPARTMENT OF MECHANICAL ENGINEERING

Possibly, as a bolt-on extra module, erasable and programmable read-only-memory

Programmable Logic Controllers (PLCs) are computers designed to automate

GOVERNMENT POLYTECHNIC CHANNAPATNA DEPARTMENT OF MECHANICAL ENGINEERING

Selection criteria of PLC:

GOVERNMENT POLYTECHNIC CHANNAPATNA DEPARTMENT OF MECHANICAL ENGINEERING

* List the function required and identify a specific type of device.

 Incoming power (power for the control system);

many applications require operator interfaces. Traditional operator interfaces include

GOVERNMENT POLYTECHNIC CHANNAPATNA DEPARTMENT OF MECHANICAL ENGINEERING

The following is a list of programming languages specified by this standard:

GOVERNMENT POLYTECHNIC CHANNAPATNA DEPARTMENT OF MECHANICAL ENGINEERING

Sequential Function Charts (SFC)

Structured Text (ST)

Programming has been developed as a more modern programming language. It is quite

Function Block Diagram (FBD)

GOVERNMENT POLYTECHNIC CHANNAPATNA DEPARTMENT OF MECHANICAL ENGINEERING

INTRODUCTION TO LADDER LOGIC

CONTACTS AND COILS

Normally Open Contact.

Normally Open Coil

GOVERNMENT POLYTECHNIC CHANNAPATNA DEPARTMENT OF MECHANICAL ENGINEERING

Below figure shows an example of a single rung ladder.

TIMERS AND COUNTERS

Many times we will want to take action in a

Simple Timers (TIM)

GOVERNMENT POLYTECHNIC CHANNAPATNA DEPARTMENT OF MECHANICAL ENGINEERING