K. J.

Somaiya College of Engineering, Mumbai-77

(A Constituent College of Somaiya Vidyavihar University)

Department of Electronics Engineering

TY
Introduction to Automation and
Course Name: Semester: B.TECH -
Mechatronics Laboratory
VI
Date of
Batch No: A3
Performance:
Faculty Name: Prof. Sandeep Hanumante Roll No: 16010222804
Faculty Sign & Date: Grade/Marks: /25
Experiment No:10

Title: Demonstration of Industry 4.0 for the error detection and emergency
operation
Aim and Objective of the Experiment:

Understand the basics of Industry 4.0 by Rapid email generation on Emergency switch
operation.

Prerequisites:

• Basics of PLC programming, IoT, networking

Objectives:

Tools required:

Theory:

Step 1 – Setting up the Electropneumatic circuit

In the initial phase of this project, the focus lies on establishing comprehensive circuit
connections and providing an overview of the selected components. The seamless integration
of these components is vital for the successful implementation of the emergency email
generation system.

The components enlisted for this project include:

 K. J. Somaiya College of Engineering, Mumbai-77

(A Constituent College of Somaiya Vidyavihar University)

Department of Electronics Engineering

COMPONENTS QUANTITY

Siemens Logo PLC 1

Flow Sensor SFAB-50U 1

5/2 Single solenoid valve 1

Pressure Regulator VPPE-3-1 1

Festo Inductive Sensor 1

Emergency Switch 1

Double Acting Cylinder 1

Flow Control Valve 2

Compressed Air pressure sensor (spau-p10r-w-g18fd-I-pnlk-pnvba-m8u) 1

 K. J. Somaiya College of Engineering, Mumbai-77

(A Constituent College of Somaiya Vidyavihar University)

Department of Electronics Engineering

Fig No.1 Siemens Logo PLC Fig No.2 Flow Sensor SFAB-50U

Fig No.3 5/2 Single solenoid valve Fig No.4 Pressure Regulator VPPE-3-1

1.1.Setting up the Electrical connections

1. Connect the Flow Sensor:

- Blue cable to 0V
- White cable to 0V
- Red cable to 24V
 K. J. Somaiya College of Engineering, Mumbai-77

(A Constituent College of Somaiya Vidyavihar University)

Department of Electronics Engineering

- Black wire connected to AQ1 on the right side of the PLC.

2. Connect the 5/2 Single Way Solenoid Valve:

- First port connected to Q1 (left side) on the output of the PLC.

- Blue cable from the second port grounded on the panel.

3. Connect the Air Pressure Sensor:

- 24V connected to the 24V of the PLC output panel.

- Q2 connected to I1/AI3.
- 0V connected to 0V.

4. Connect the Emergency Switch:

- Ports 1 and 2 shorted.

- Port 3 connected to Q1 (right side) of the PLC output panel.
- Port 4 grounded.
- Port 5 connected to I4 of PLC.
- Port 6 connected to the 24V of the panel.

5. Connect the Detent Switch:

- Connected to Q2 (right side).

- Q2 (left side) connected to the 24V of the panel.
- The other end grounded to 0V of the panel.

6. Connect Pushbutton 2 (NC Contact):

- One end connected to the 24V of the panel.

- Other end connected to I5 of the PLC output panel.

7. Connect Pushbutton 1 (NO Contact):

- One end connected to 24V.

- Other end connected to I2 of the PLC output panel.

8. Connect Pushbutton 3:

- One end connected to 24V.

- Other end connected to I10 of the PLC output panel.

9. Connect the Inductive Sensor:

- 0V grounded on the panel.

 K. J. Somaiya College of Engineering, Mumbai-77

(A Constituent College of Somaiya Vidyavihar University)

Department of Electronics Engineering

- 24V connected to 24V of the source.

- Q1 connected to I9 of the PLC output panel.

Step 2 – Setting up the Communication Network

In this following section, we embark on the critical steps of configuring the infrastructure and
software components essential for the seamless operation of our project. This encompasses
adapting settings for the WLAN access point to establish a robust network, setting a static IP
address for the LOGO! PLC, aligning the network according to the positional sketch, configuring
the OPC server for efficient data exchange, and commissioning the measuring software.

COMPONENTS/SOFTWARES QUANTITY

Dlink Wifi Modem 1

Wifi router 1

Ethernet Cables 1

Windows console -

Internet Explorer -

TP 260 Software -

LOGO!Soft Comfort 8.1 -

STEPS TAKEN:
 K. J. Somaiya College of Engineering, Mumbai-77

(A Constituent College of Somaiya Vidyavihar University)

Department of Electronics Engineering

1. Network Connection:

- Set up the network connection according to the provided figure, connecting all components
over a single network.

2. Change Adapter Settings on Main Computer:

- In the main computer, change the adapter settings to match the IP address of the LOGO PLC.
- Access Control Panel > Network and Connections > Ethernet Properties.
- Select Internet Protocol Version 4 (TCP/IPV4) properties.
- Change the IP address and subnet mask under "Use the following IP address."
- Verify the updated IP address using "ipconfig" in the Command Prompt.

3. Create XML File:

 K. J. Somaiya College of Engineering, Mumbai-77

(A Constituent College of Somaiya Vidyavihar University)

Department of Electronics Engineering

- Create an XML file in Notepad with the extension .xml.

- Include the email addresses of the sender and receiver, modifiable according to the purpose.
- Obtain a dummy password from the Google account's security settings, generated through 2-
step verification and App passwords. Use this password in the XML file.
 K. J. Somaiya College of Engineering, Mumbai-77

(A Constituent College of Somaiya Vidyavihar University)

Department of Electronics Engineering

4. Check PLC Connection:

- Verify the connection between the PLC and the device by entering "ping 192.168.1.10" in the
Command Prompt.

5. Load Logo Soft Comfort Software:

- Load the Logo Soft Comfort software with the PLC program.
- Put the PLC in run mode through the software.
 K. J. Somaiya College of Engineering, Mumbai-77

(A Constituent College of Somaiya Vidyavihar University)

Department of Electronics Engineering

6. Network Setup According to Positional Sketch:

- Set up the network according to the positional sketch.

- Verify the configuration to ensure proper communication.

7. Configure OPC Server:

- Open TP260 Operator panel in setup mode.

- Click on connect OPC, then select the desired pressure.
- Run the setup by clicking on "Setup Ready."

8. Enter Receiver's Email in Operator Mode:

 K. J. Somaiya College of Engineering, Mumbai-77

(A Constituent College of Somaiya Vidyavihar University)

Department of Electronics Engineering

- In operator mode, on the right side text box, enter the receiver's email.
- Press the save option.

9. **Start System and Create Disturbance:**

- Once the entire setup is ready and running, start the system with the push button.

- Create a disturbance using the emergency stop button to trigger an email notification to the
receiver.
K. J. Somaiya College of Engineering, Mumbai-77

(A Constituent College of Somaiya Vidyavihar University)

Department of Electronics Engineering

 K. J. Somaiya College of Engineering, Mumbai-77

(A Constituent College of Somaiya Vidyavihar University)

Department of Electronics Engineering

Control Console:

Stepwise-Procedure:

- Develop the program in TIA portal

- Download the program to S7-1200 PLC
- Connect the Ios of the MPS station and Control panel of the Distribution/Conveyor station
- Turn on the pneumatic supply
- Test the program
/
Experiment Results:
K. J. Somaiya College of Engineering, Mumbai-77

(A Constituent College of Somaiya Vidyavihar University)

Department of Electronics Engineering

K. J. Somaiya College of Engineering, Mumbai-77

(A Constituent College of Somaiya Vidyavihar University)

Department of Electronics Engineering

K. J. Somaiya College of Engineering, Mumbai-77

(A Constituent College of Somaiya Vidyavihar University)

Department of Electronics Engineering

K. J. Somaiya College of Engineering, Mumbai-77

(A Constituent College of Somaiya Vidyavihar University)

Department of Electronics Engineering

 K. J. Somaiya College of Engineering, Mumbai-77

(A Constituent College of Somaiya Vidyavihar University)

Department of Electronics Engineering

Post Lab Subjective/Objective type Questions:

1. What are the IO s used in the Distribution/Conveyor station?

Conclusion:

Hence, we have successfully completed the experiment of demonstration of Industry 4.0 for the
error detection and emergency operation

Signature of faculty in-charge with Date: