Assignment

Industrial Automation and Process

Control (EC4511)
Year 4 –Semester 2

Name : unknown

Registration No : unkonwn

Date of Submission: 06.10.2018

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Introduction
This assignment STEP 7 MicroWIN software used to design the Control a simple automated
system. A programmable logic controller (PLC) or programmable controller is an industrial
digital computer which has been ruggedized and adapted for the control of manufacturing
processes, or robotic devices, such as assembly lines, or any activity that requires high
reliability control and ease of programming and process fault diagnosis.

This case we abled to develop a conveyer belt with six sensors and three actuators to detect
the objects on the conveyer belt in different sizes.

S, A, B, C, D and E are normally open photo sensors which are placed on the same horizontal
level. Two actuators A2 and A3 that push the items and actuator A1 is used for stamping.
The functionality of the PLC has evolved over the years to include sequential relay control,
motion control, process control, distributed control systems, and networking. The data
handling, storage, processing power, and communication capabilities of some modern PLCs
are approximately equivalent to desktop computers. PLC-like programming combined with
remote I/O hardware, allow a general-purpose desktop computer to overlap some PLCs in
certain applications. Desktop computer controllers have not been generally accepted in heavy
industry because the desktop computers run on less stable operating systems than do PLCs,
and because the desktop computer hardware is typically not designed to the same levels of
tolerance to temperature, humidity, vibration, and longevity as the processors used in PLCs.
Operating systems such as Windows do not lend themselves to deterministic logic execution,
with the result that the controller may not always respond to changes of input status with the
consistency in timing expected from PLCs. Desktop logic applications find use in less critical
situations, such as laboratory automation and use in small facilities where the application is
less demanding and critical, because they are generally much less expensive than PLCs

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Design Procedure

Blocks having a length greater than length AC then ejected by actuator A2.

Blocks having a length equal or greater than length AB and less than length AC then to be ejected
by actuator A3.

The blocks satisfying neither the conditions are to be stamped by the actuator A1.

There may be more than one blocks on the conveyer at a given time so there should be sufficient
time for the stamping actuator to go down and come up.

The sensor S detects if a block is placed on the conveyor and the belt should start moving when
there is an item in the conveyor and while it is being processed.

If there is no item the conveyor should be stopped.

If a second block is placed while another block is being processed, the cycle should complete
when the processing of the second block is finished.
Design the Ladder logic programmer for satisfied this conditions.

INPUTS OUTPUTS
SENSOR_S I0.0 Sensor 1 ACT_STMP Q0.0 Actuator1
SENSOR_A I0.1 Sensor 2 ACT_LO Q0.1 Actuator2
SENSOR_B I0.2 Sensor 3 ACT_SO Q0.2 Actuator3
SENSOR_C I0.3 Sensor 4 MOTOR Q0.4 Motor
SENSOR_D I0.4 Sensor 5 INDICATOR Q0.5 indicator
SENSOR_E I0.5 Sensor 6
RST I0.6

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Connect the necessary supply lines and common lines for the system to operate. Connect the
necessary sensors in the system to the PLC units and connect the actuators and motors to the
outputs of the PLC. The PLC programme uploaded to PLC 222 CPU and run the porgramme
in PC.

The test environment wooden plate used to create PLC inputs outputs wiring system and the
structure of the system is on the wooden platform.

A1 is the Double acting cylinder and A2, A3 are single acting cylinders, motor is the 24V DC
motor and conveyor belt, power supply, Electropneumatic valves.

Final design is the conveyer with six sensors for detected different length objects on the
conveyer belt with comparing distances between A and B,A and C.Actuators used to
stamping and eject the invalid objectives on the conveyor belt.

Simulation results available in the appendix part.

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Discussion and Conclusion
In the design simulation initial state think about inputs and outputs of the system.There are
six optical sensors and assigned as inputs of the system. Otherwise the five output states in
the system.A1,A2,A3 actuators, Motor and Indicator are assigned as an Output of the
system.Up Down counters are used for count objects and Timers used for active some outputs
in system.

Network1.
Start sensor is normally closed this check about block is on the rail or not.
Network2.
CNT_ is on the DC motor is start.
Network3.
The counter is decreased M3.0 is on and counter worked as down counter.
Network4.
Check whether the object is larger than AC detect by sensor A, sensor B and sensor C M0.0
memory bit is on.
Network5.
M0.0 memory bit is on the timer is active after 25.5second.
Network6.
Timer is on M0.1 memory bit is on and the block is near then save the statues in memory.
Networke7.
Forward stroke of actuator.
Network8.
M0.1 is on, ejection wait until 1second.
Network9.
Ejection completion save as M0.2 memory bit.
Network10, Network11, Network12, Network13, Network14, Network15
The block is smaller than AB length stamping the box.
Network16.
M1.1 memory bit is on the counter is on and count invalid objects.
Network 17.
The indicator is on counter is finish the count.
Network18.
The sensor A and B are detected the object but not all sensors are detected, M2.0 memory bit
is on.
Network19.
Sensor A is not detected but sensor B and sensor C are detected
Network20, Network21.
After detecting C timer turns on.
Network22, Network23.
Released injected stroke after 5s.
Network24, Network25.
A3 actuation.

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Network 26 check for sensor E
Issues faced during the designing

There are many types of issues based on the simulation and design. The sensors have some
distance errors. A, B, C, D sensors have some length position errors in practical situation and
it hard to detect what is the length of objects in the conveyer belt.
The conveyor belt is not correctly alignment and it occurred to object detection errors and
some time the object is not attend the correct place in suitable time so the sensors unable to
detected the object on rail.
The time calculations errors with the correct distances. When this errors is occurred the
stamping actuatorA1, eject actuators (A2,A3) are not working at correct time slots and
objects can not eject or stamping on time.

The PLC simulations consider about ladder logics they are many timers and counters with
different logic conditions and simulation process we want to check about optimal decision
and get solutions.so the memory bits have some small errors Timers or counters not working
properly and accuracy of the detecting system become faults.

Conclusion.

The experiment is successful and the PLC ladder programme work mostly positively and
after doing this experiment we abled to design simple automated system using a Programmable
Logic Controllers and good understood about how to work w ith PLC.

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References

 Maher, Michael J. Real-Time Control and Communications. 18th Annual ESD/SMI

International Programmable Controllers Conference Proceedings, 1989,

 Kinner, Russell H., P.E. Designing Programmable Controller Application Programs Using
More than One Designer. 14th Annual International Programmable Controllers Conference
Proceedings, 1985

 W. Bolton, Programmable Logic Controllers, Fifth Edition, Newnes, 2009 ISBN 978-1-

85617-751-1, Chapter 1

 Keller, William L Jr. Grafcet, A Functional Chart for Sequential Processes, 14th
Annual International Programmable Controllers Conference Proceedings, 1984

 M. A. Laughton, D. J. Warne (ed), Electrical Engineer's Reference book, 16th

edition,Newnes, 2003 Chapter 16 Programmable Controller

 "The father of invention: Dick Morley looks back on the 40th anniversary of the PLC".
Manufacturing Automation. 12 September 2008.

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Appendix

Ladder logic digram

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Figure1 S7_200 simulate model

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Figure 2

Figure 3

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Figure 4

Figure 5

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Figure 6

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Figure 7

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