Designing a Process Controller

Using PLC
Course Code: EEE 402
Sec: 02
Group : 1

Course Instructor : Dr. Muhammed Mazharul Islam

Group Members

1. Md Arif Uddin (2018-1-80-034)

2. Umme Fariha (2018-1-80-071)
3. Foysal Ahmmed (2018-1-80-082)
4. K. M Rubayet Islam (2019-1-80-004)
5. Muhammad Suja Akbar (2019-1-80-054)
6. Abu Ayub Sajib (2019-1-80-028)

Date of Submission : 12.09.22

 Table Of Contents
Content Slide Number
System Description 3
Proposed solution 4
Alternative Solution 5
Diagram 6-7
Tuning Process 8
Performance Evalution 9-10
Conclusion 11
Refferences 12

2
 System Description
 PLC (programmable logic controller) which can receive data as inputs and
send operating instructions as outputs. It can be programmed to take inputs
from either automated data capture points or from switches/ buttons.

 Here, we will design a controller for controlling the heater.

 Two switches such as ‘on’ and ‘off’ were introduced to switch the heater.

 PLC controller mainly used to keep the heater temperature steady to

follow some criteria. Those are :-

(1) steady state error swing no more than ± 2º C

(2) Settle to a changed temperature within 5s

(3) Temperature overshoot limited to 5º C

3
 Proposed Solution
 For our design, we have used Analog control system based
design.

 The heater was controlled using a setpoint value and ON

and OFF switches were utilized for switching mechanism.

 In our design the steady state error more than 2º C and overshoot
limit cross the 5%.

4
 Alternative Solution
Due to the shortage of practice hour in the regular days, we couldn’t
find any accurate alternative solution. However we tired build a
design using the PID Controller which doesn’t meet the criteria.
That’s why we are not giving any alternative solution for our designed
system.

5
 Diagram

6
Figure - 1: Ladder diagram of our proposed system
 Diagram

Figure - 2 : Simulation of our proposed system 7

 Tuning Process
 Simatic S7-1200 analogue 1/0 signal board SM 1234 (sl. No.
6ES7234-4HE30-0xB0) was used in our system which has a
voltage and current range of +/- 10 V and 0-20 mA respectively.
[1]

 The full-scale data word for a used range of 0-10 V would be 0

to 27,648. The normal x and scale x function blocks used to
convert these values to a temperature scale. [2]

 A digital port is used to turn on the heater, and an LED will

indicate if the heater is turned on or not.

o ON: A digital port to command the PLC to turn the heater on.

o OFF: A digital port to command the PLC to turn the heater off.
8
 Performance Evaluation
 We put our best effort for designing and the double switching was also utilized here. The heater was
controlled with necessary logical data.

 The system turned ON after clicking the ON switch and the display shows the set value we have
assigned. The present value increases as the heater is turned on.

9
 Performance Evaluation
 However, the designed solution doesn’t get stable. The present value is continuously
increasing even after reaching the set value limit. But the OFF switch worked properly.
Pressing the OFF switch immediately decreases the present value to zero.

10
 Conclusion
 In this project, we have tried to designed a PLC base control
system for heaters.

 We have used ON and OFF switches for switching mechanism

and utilized the analog control system design for our system.

 There was some problems regarding the initial starting conditions

but there are room for future improvements.

 This project not only deepened our understanding towards heat

control but also enriched our knowledge and skills regarding PLC
controllers.

11
 References
[1]https://www.process-heating.com/articles/89746-use-a-plc-or-
stand-alone-temperature-control

[2]https://www.youtube.com/watch?
v=su1LT1P_uxo&feature=share&fbclid=IwAR0LbDHyqKQ53_QFG
0Hz2wSGwCQy5LqHrpzGAClATo4MmJFELanvIWo1gC4

12