Automation of an industrial drill

Student: Beñat Mateo Goñi

Teacher: Ane Sanles
Class: 2 ARI
Date: 2024/01/15
INDEX:

● Cover

● Index Pg.1

● Report Pg.2

○ Descriptive report
■ Goal
■ Justification
■ Description of the process Pg.3

■ Introduction
● TIA PORTAL Pg.5-7

■ Conclusions and summary

● EPLAN blueprints Pg.8

○ General protections and power diagram

○ Control diagram
○ PLC control diagram
○ Terminal connections Pg10

○ Grafcet (FluidSIM)

● Annexes
○ Cade Simu Pg.11

● Specification sheet Pg.12

○ General conditions
○ Equipment and material conditions Pg.13

○ Economic budget Pg.14

1
 REPORT:

In this report we will be making the electrical

blueprints and schemes for a drilling machine to provide an
efficient solution for our client. We will be showing the final
result of the automatization process and how it works, as
well as the choice of the control system for the drilling
machine.

Descriptive report:

Our goal is to create an efficient and secure machine that will allow the worker
doing the drilling process without any superior knowledge and taking any unnecessary
risks, apart from that, we will be choosing the best way to control the machine (Either
by PLC or a wired version)

In order to ensure the security of the worker, we will be using the necessary
protections for the electrical scheme, such as magnetothermics, fuses and relays, as
well as a correctly designed circuit to avoid short circuits or jamming between
contactors.

Description of the process:

First of all, every security measure and mechanism must be alright when it
comes to the functioning of the electrical sequence.

Once everything is alright, the operator will be given to choose between a

manual or automatic mode, on the one hand, the manual mode will work as it follows;

Manual mode:

By pressing S3, the drill bit will start rotating (Activating KM3) , after that, the
drill will be ready to lower the head by pressing S4 (KM2 activated), once it arrives the
bottom limit switch KM2 will deactivate and it will wait for 5 seconds, after which, the
drill bit will stop (KM3) and KM1 will activate moving the drill upwards until it reaches
the upper limit switch.

2
 Automatic mode:

On the other hand, if the automatic mode is chosen, the process will be the
same as the previous one but it will automatically start lowering the head after
pressing S3. so that there is no need to press the S4 button.

STOP:

If by any chance the S1 (Stop) button is pressed, the system will automatically
stop, and the only way to move the drill upwards will be by pressing the S5 button.

The lights and indicators will work as follows:

- Drill bit rotation: H1 (Green)

- Head movement: H2 (Blue)
- System in standby or ready to operate: H3 (Yellow)
- Fault: H4 (Red)

Realization:

In order to design and plan this project, various softwares have been needed, thanks to
them, we have been able to create high quality schemes and diagrams as well as
programs.

To begin with, the first thing we made was the Grafcet via the software FluidSIM, this
one consists of 6 Steps including the emergency stop.

By making this scheme, we ensure the correct functioning of the program that will
follow in TIA Portal:

3
GRAFCET:

4
 TIA Portal programming:

Modes:

Initial conditions:

Grafcet steps:

5
Stop:

6
Activations:

Indicators:

7
HMI:

A simple programming has been made, which will inform about every essential thing to
the worker, and it will also provide a simple functioning so that it is easy to understand
even if the worker has not any further qualifications.

Thanks to the programming in TIA Portal, the company will always be able to add new
features and improvements to the program.

8
Cade_Simu:

To ensure the correct functioning of the wired scheme, we have created it in CadeSimu,
which offers us the ability to simulate the process, this way we know that everything is
correctly wired.

9
Conclusion and summary:

To summarize everything, we have created both types of control systems, and after
analyzing both results we thought that the best solution would be according to the
needs of the company.

If the company plans to add new features to the drilling, specially the ones that
need a high accuracy on the hole making or thinks of adding it to the production line, a
PLC control would be the best option, since it works in a much higher precision and it
would allow an automatic control without the need of a worker.

In spite of the advantages that the PLC control offers, we personally think that a
wired control of the drill would be enough to commit its purpose and it would halve the
price of the total cost .

In the end, its the company’s choice on whether they want a PLC or a wired
control of the drilling machine.

10
 0 1 2 3 4 5 6 7 8 9

2 Control Scheme.8 / L1 L1 / 2 Control Scheme.1

2 Control Scheme.8 / L2 L2 / 2 Control Scheme.1

2 Control Scheme.8 / L3 L3 / 2 Control Scheme.1

2 Control Scheme.8 / N N/ 2 Control Scheme.1

1 3 5 7

Q1
1 3 5

F2 I> I> I> I>

2 4 6 2 4 6 8

N (Control) / S.1
L (Control) / S.1
1 3 5 1 3 5

KM2 KM3
S.4 S.2 1 3 5
2 4 6 2 4 6
KM1
S.6 2 4 6

1 3 5
F1
S.2 2 4 6

U1 V1 W1 U1 V1 W1

M M
M1 M1
2 Control Scheme.6 3~ 2 Control Scheme.3 3~
PE PE

PE PE
2 Control Scheme.6 2 Control Scheme.4

1 Bornes
Fecha 15/01/2024 EPLAN Esquema de potencia =
Resp. benat BEÑAT MATEO GOÑI +
Probado Proyecto básico con estructura de designación totalmente numerada Num_bas001 Hoja
2 Control Scheme
Cambio Fecha Nombre Original Sustitución por Sustituido por Página 2/5
 0 1 2 3 4 5 6 7 8 9

Plano de conexiones de bornes F11_001

benat 15/01/2024
Destinos internos

1 3 5 7
11 13 11 13 13 13 11

I> I> I> I>

12 14 12 14 14 14 12 2 4 6 8

FC1 KM2 FC2 KM1 S2 FC2 F1 Q1

12 11 14 13 12 11 14 13 14 13 14 13 11 12 7 1 2 3 4 5 6 8

BK BK BK BU

W5 W2 W4 W1
ÖLFLEX® CLASSIC
100

X1

Puentes

Borne

Punto de conexión

4
1

1
W3

BK
11 12 11 12 11 12 11 12 13 14 17 18 13 14 PE U1 V1 W1

KM1 FC1 KM2 FC2 FC1 KT1 FC2 M1

U1 V1 W1
11 11 11 11 13 17 13
M
3~
12 12 12 12 14 18 14 PE
Destinos externos

2 Control Scheme General Protections

Fecha 15/01/2024 EPLAN EPLAN GmbH & Co. KG Plano de conexiones de bornes X1 =
Resp. benat +
Probado Proyecto básico con estructura de designación totalmente numerada Num_bas001 Hoja Bornes
Cambio Fecha Nombre Original Sustitución por Sustituido por Página 3/5
 0 1 2 3 4 5 6 7 8 9

Q2

Q1

1 2 1 2 BK
General Protections.7 / PE L1 / General Protections.1
I>

3 4 3 4 GY
General Protections.7 / L3 L2 / General Protections.1
I>

5 6 5 6 BN
General Protections.7 / L2 L3 / General Protections.1
I>

7 8 7 8 BU
General Protections.7 / L1 PE / General Protections.1
I>

W1
General Protections.3
ÖLFLEX® CLASSIC 100
4X0,75
300/500V
Manguera de Conexionado

Bornes S
Fecha 15/01/2024 EPLAN Hoja de título =
Resp. benat BEÑAT MATEO GOÑI +
Probado Proyecto básico con estructura de designación totalmente numerada Num_bas001 General
Hoja Protections
Cambio Fecha Nombre Original Sustitución por Sustituido por Página 4/5
 0 1 2 3 4 5 6 7 8 9

2 Control Scheme.7 / L (Control) L (Mando) /

15
If S2 is pressed = MANUAL MODE
AUTO MODE
F1
2 Control Scheme.3 16 18

11
11 KM1
S.6
S1 12
12

13 13 11 13 13 13 13 17 13 13 13 11
S3 KM3 S2 KM4 S4 KM2 S5 KT1 KM1 KM1 KM2 KM2
14 S.2 14 12 S.3 14 14 S.4 14 14 S.8 18 S.6 14 S.6 14 S.4 14 S.4 12

11
KM3
S.2 12
17 11 11 13

KT1 SQ2 SQ1 SQ2

S.8 18 S.8 S.4
12 12 14

A1 x1 A1 A1 A1 x1 x1 A1 x1
KM3 H1 KM4 KM2 KM1 H2 H3 KT1 H4
A2 x2 A2 A2 A2 x2 x2 A2 x2

2 Control Scheme.7 / N (Control) N (Mando) /

1 2 13 14 S.4 1 2 1 2 17 18 S.6
3 4 3 4 3 4
5 6 2 Control Scheme.4 5 6 2 Control Scheme.3 5 6 2 Control Scheme.6 17 18 S.2

11 12 S.8 11 12 S.8 11 12 S.8

13 14 S.3 13 14 S.5 13 14 S.6
13 14 S.7 13 14 S.7

General Protections
Fecha 15/01/2024 EPLAN Esquema de mando =
Resp. benat BEÑAT MATEO GOÑI +
Probado Proyecto básico con estructura de designación totalmente numerada Num_bas001 Hoja S
Cambio Fecha Nombre Original Sustitución por Sustituido por Página 5/5
 (IC)

0 Reset Every Contactor and Light, (SET H3)

(Auto) S3 * S2 (Manual) S3 * S2

1 Set KM3, KM2 and H3 OFF 2 Set KM3, H1 (Green) ON and H3 OFF

(Lower Head) S4

3 Set KM2 and H2 (BLUE) ON

(Lower Limit Switch) SQ_2 (Stop pressed during process) S1 * CI

4 E_Stop RES EveryStep and Activations, H4 ON

Reset KM2 and H2 OFF

(TON) 5_Seconds (Raise Head) S5

5 RES KM3 (H1,H3 OFF) and Set KM1 (H2 ON)

(Upper Limit Switch) SQ_1

 0 1 2 3 4 5 6 7 8 9

1.a.6 / 4L1
/ 5L1

1.a.6 / 4N

1.a.7 / 5NN
R2
/ 2TT
x1 x2

x1

-V1 R1
24VDC/ 5A
x2
RB1
x2 x1

PT100
x1 x2

RB2
x2 x1
+24Vcc

x1 x1

R3 R4
x2 x2

0Vss

RESERVE

RESERVE

RESERVE

RESERVE

RESERVE

RESERVE

RESERVE

RESERVE

RESERVE

RESERVE

RESERVE

RESERVE

RESERVE

RESERVE

RESERVE

RESERVE
-K1
SIE.6ES7214-IBG40

L1 N FE L+ M 1M DI a.0 DI a.1 DI a.2 DI a.3 DI a.4 DI a.5 DI a.6 DI a.7 DI b.0 DI b.1 DI b.2 DI b.3 DI b.4 DI b.5 2M AI 0 AI 1
-X10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 -X11 1 2 3

IWX+2
IX+1.0

IX+1.1

IX+1.2

IX+1.3

IX+1.4

IX+1.5

IWX
IX.0

IX.1

IX.2

IX.3

IX.4

IX.5

IX.6

IX.7
AC ~ -

+
- -
+

6ES7214-1BG40-0XB0 CPU 1214C AC/DC/RLY S7-1200 SIEMENS

N(-) N(-)
_ _
~ ~
L(+) L(+)
QX+1.0

QX+1.1
QX.0

QX.1

QX.2

QX.3

QX.4

QX.5

QX.6

QX.7

-X12 1 2 3 4 5 6 7 8 9 10 11 12
1L DQ a.0 DQ a.1 DQ a.2 DQ a.3 DQ a.4 2L DQ a.5 DQ a.6 DQ a.7 DQ b.0 DQ b.1
RESERVE

RESERVE

RESERVE

RESERVE

RESERVE

RESERVE

RESERVE

RESERVE

RESERVE

RESERVE

1.c
Fecha 08/10/2023 EPLAN CIP ESTELLA Hoja de título = CA1
Resp. benat + EAA
Probado Proyecto básico con estructura de designación según los estándares IEC: Estructura de página con designación de función y designación de localización IEC_bas001 Hoja 2
Cambio Fecha Nombre Original Sustitución por Sustituido por Página 5/5
 Used materials (DIRECT COSTS) Used materials (DIRECT COSTS)
Quantity Material Unitary price Total price Quantity Material Unitary price Total price
1 HMI 667,90€ 667,90€ 2 Buttons 8,69€ 17,38€
1 PLC 751,00€ 751,00€ 1 Emergency stop 22,68€ 22,68€
1 50 m PROFINET wire spool 26,49€ 26,49€ 1 Wires 26,49€ 26,49€
1 Magneto 49,99€ 49,99€ 1 Magneto 49,99€ 49,99€
1 Relays 84,95€ 84,95€ 1 Relays 84,95€ 84,95€
1 Fuses 216,15€ 216,15€ 1 Fuses 216,15€ 216,15€
3 Contactors 29,92€ 89,76€ 5 Contactors 29,92€ 149,60€
1 Motor axis 181,99€ 181,99€ 1 Motor axis 181,99€ 181,99€
1 Motor updown 88,00€ 88,00€ 1 Motor updown 88,00€ 88,00€
TOTAL 2.156,23€ 1 Lights 11,99€ 11,99€
TOTAL 837,23€

Materials from workers are taken for granted

Labour (DIRECT COSTS) Labour (DIRECT COSTS)

Quantity Employee's qualification Nº of hours Unitary price Total price Quantity Employee's qualification Nº of hours Unitary price Total price
1 PLC and HMI Programmer 8 20€ 160,00€ 2 Electricians 8 17€ 272,00€
1 PLC technician, with wiring knowledge 5 17€ 85,00€
1 Electrician 12 17€ 204,00€
TOTAL 449,00€ TOTAL 272,00€

DIRECT COSTS 2.605,23€ DIRECT COSTS 1.109,23€

INDIRECT COSTS 44,90€ INDIRECT COSTS 27,20€

MEB (Material execution budget) 2.650,13€ MEB (Material execution budget) 1.136,43€

GE (General expenses) 344,517 € GE (General expenses) 147,736 €

IP (Industrial profit) 212,010€ IP (Industrial profit) 90,914€

TC (Total project cost) 3.206,657 € TC (Total project cost) 1.375,080 €

PF (Professional fees) 424,021 € PF (Professional fees) 181,829 €

CEB (Contract execution budget) 3.880,055 € CEB (Contract execution budget) 1.663,847 €

TB (Total budget) 4.304,076 € TB (Total budget) 1.845,676 €

VAT = 21,00%
Specification sheet:
General conditions:

When it comes to the laws and regulations for this project, we will have to bear in mind
the 3 most important standards:

ISO 12100:2010 - Security in machines: Ensuring the correct work of them and
safety procedures

ISO 45001:2018 - Systems for the security of the worker.

ISO 9001:2015 - System for the quality of the product.

UNE-EN 60439: Low Voltage switchgear assemblies.

Equipment:

We will need equipment to do the installation, as mentioned above, this

equipment has to be a good one according to the ISO laws. General protections for the
worker, such as electrician screwdrivers (isolated), gloves, polymeter and helmet will
be essential to carry out the job.

In the following page a detailed description of the materials and a budget of the
project will be shown:

11