PLC BASED DRAW BRIDGE AUTOMATION

CHAPTER 1
INTRODUCTION
A bridge over a navigable waterway must allow boats and ships to cross its
path, usually by being tall enough to allow them to sail underneath it. Sometimes it is
impractical to build a bridge high enough; for example, it may rise too steeply or
block the view of an important landmark. In such cases, the bridge can be designed so
it can be easily moved out of the way for vessels that are too large to sail under it. The
type of movable bridge that most people think of as a draw bridge is similar to those
that spanned medieval castle moats.
Technically called "bascule bridges" from the French word for seesaw, they may open
at one end and lift to one side (single leaf) or open in the middle and lift to both sides
(double leaf). Another common type of movable bridge is the vertical lift span, in
which the movable section is supported at both ends and is raised vertically like an
elevator.
Programmable Logic Controllers (PLCs), also referred to as programmable
controllers, are in the computer family. They are used in commercial and industrial
applications. A PLC monitors inputs, makes decisions based on its program, and
controls outputs to automate a process machine[1].

Fig 1.1- Typical Draw- Bridge.

This project is to design and construct a DRAWBRIDGE using a programmable logic
controller. Inductive sensor is used to know the ship position. PLC (micrologix200) is
used for this purpose. Ship is detected by Inductive sensor which is placed at certain
distance from the bridge. Sensor output provides input to the PLC and it‟ll drive DC
motor, Servo motor and Signal Poles according to programming.

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CHAPTER 2

LITERATURE REVIEW

Muhammad Arshad Khattak et al expressed his idea related to interfacing of Sensor

with PLC in one of his paper. The main object of their paper was to design and
simulate an intelligent traffic control system. The system developed is able to detect
the presence or absence of vehicles within certain range by setting the appropriate
duration for the traffic signals to react accordingly. By employing mathematical
functions to calculate the appropriate timing for the green signal to on, the system can
help to solve the problem of traffic congestion. Hardware simulation tests were
successfully performed on the algorithm implemented into a PLC [4].
Drawbridge control design has remained almost static since the early 1920's; being
based on Ranual torque control of wound-rotor motors and crude relay logic to
enforce the interlock sequences. The maturation of solid-state electronic variable
speed controls far aotors, Programmable Logic Controllers, and electronic sensors
offer the control designer many new options.
Medieval castles were usually defended by a ditch or moat, crossed by wooden
bridge.In early castles the bridge might be designed to be destroyed or removed in the
event of an attack, but drawbridges became very common. A typical arrangement
would have the drawbridge immediately outside a gatehouse, consisting of a wooden
deck with one edge hinged or pivoting at the gatehouse threshold, so that in the raised
position the bridge would be flush against the gate, forming an additional barrier to
entry. It would be backed by one or more portcullises and gates. Access to the bridge
could be resisted with missiles from machicolations above or arrow slits in flanking
towers.

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CHAPTER 3
3.1 OBJECTIVES
 To allow passage to huge gigantic cargo ships on the canals or lagoons.

 To automate the process of ship detection, opening or closing of a bridge,

controlling the signals and road barriers.

 Replace the manual system which is currently used, compare the time and
manpower requirement for both the existing system with the proposed
automated system.

3.2 METHODOLOGY
We are designing this system to control the process of opening and closing
bridge automatically when ship will be detected. Ship would be detected by Inductive
Sensors located at the either side of the bridge. When ship will be detected it
sends high to low pulse to PLC. As soon as PLC gets high to low signal it drives the
DC to close road barriers and signal changes from green to red. Then after PLC drives
Servo motor to open the bridge and it will continuously monitor the states of
Proximity sensor. Proximity sensor is used to check the status of the bridge, whether
bridge is open or not. As PLC gets signal from Proximity sensor it would stop Servo
motor. Hence the bridge is opened. As soon as ship passes through the bridge it‟ll
detect by sensor at other side of the bridge and it will send high to low signal to PLC.
PLC first drives Servo motor in reverse direction until bridge is totally closed. Then
road barrier will be opened and signal changes from red to green.

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3.3 SYSTEEM BLOCK DIAGRAM

SHIP SERVO
DETECTOR 1
MOTOR
1

PLC DC
MOTOR

SHIP
DETECTOR 2 SIGNAL
TIMER
LAMP

FIG 3.3. SYSTEM BLOCK DIAGRAM

FIG 3.4 CONCEPTUAL SYSTEM DIAGRAM

Each draw bridge is a unique structure designed for its particular location and
traffic needs. There are at least half a dozen different design concepts, but the most
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common is the bascule type. In double-leaf or four-leaf (a double-leaf bridge with

separate leaves for each direction of vehicular traffic) bascule bridges, each leaf can
be raised and lowered independently. The energy required rising and lower the
bascule leaves is greatly reduced by counterbalancing each leaf with a compact
weight on the opposite side of the pivot axle (turn-on). In various bascule designs, this
counterweight might be located above the roadway and allowed to pivot below the
roadway as the bridge is raised, or it might be located below the roadway and allowed
to descend into a basement level (often well below the waterline) as the bridge opens.
It might be located adjacent to the turn-on or, for greater leverage, be set back a few
yards(meters). As an example, each pair of 500-ton (450-metric-ton) leaves on the
Casco Bay Bridge is balanced with an 800-ton (720-metric-ton) counterweight. The
lift mechanism is usually a rack-and-pinion gear arrangement driven by electric
motors [2].

3.5 INVENTION AND EARLY DEVELOPMENT OF PLC

In 1968 GM Hydra-Matic (the automatic transmission division of General

Motors) issued a request for proposals for an electronic replacement for hard-wired
relay systems based on a white paper written 223 Associates' eighty-fourth project,
was the result. Bedford Associates started a new company dedicated to developing,
manufacturing, selling, and servicing this new product: Modicon, which stood for
MODULAR DIGITAL CONTROLLER. One of the people who worked on that
project was Dick Morley, who is considered to be the "father" of the PLC. The
Modicon brand was sold in 1977 to Gould Electronics, later acquired by German
Company AEG, and then by French Schneider Electric, the current owner. One of the
very first 084 models built is now on display at Schneider Electric's facility in North
Andover, Massachusetts. It was presented to Modicon by GM, when the unit was
retired after nearly twenty years of uninterrupted service. Modicon used the 84
moniker at the end of its product range until the 984 made its appearance. The
automotive industry is still one of the largest users of PLCs.

Early PLCs were designed to replace relay logic systems. These PLCs were
programmed in "ladder logic", which strongly resembles a schematic diagram of relay
logic. This program notation was chosen to reduce training demands for the existing
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technicians. Other early PLCs used a form of instruction list programming, based on a
stack-based logic solver.

Modern PLCs can be programmed in a variety of ways, from the relay-derived

ladder logic to programming languages such as specially adapted dialects of BASIC
and C. Another method is state logic, a very high-level programming language
designed to program PLCs based on state transition diagrams. The majority of PLC
systems today adhere to the IEC 61131/3 control systems programming standard that
defines 5 languages: Ladder Diagram (LD), Structured Text (ST), Function Block
Diagram (FBD), Instruction List (IL) and Sequential Flow Chart (SFC).

Many early PLCs did not have accompanying programming terminals that were
capable of graphical representation of the logic, and so the logic was instead
represented as a series of logic expressions in some version of Boolean format, similar
to Boolean algebra. As programming terminals evolved, it became more common for
ladder logic to be used, for the aforementioned reasons and because it was a familiar
format used for electromechanical control panels. Newer formats such as state logic
and Function Block (which is similar to the way logic is depicted when using digital
integrated logic circuits) exist, but they are still not as popular as ladder logic. A
primary reason for this is that PLCs solve the logic in a predictable and repeating
sequence, and ladder logic allows the programmer (the person writing the logic) to see
any issues with the timing of the logic sequence more easily than would be possible in
other formats.

Programmable logic controllers can also be specified with a number of computer

interface options, network specifications and features. PLC power options, mounting
options and environmental operating conditions are all also important to consider.

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3.6 ARCHITECTECTURE OF PLC

FIG 3.6 ARCHITECTECTURE OF PLC

A basic PLC system consists of the following sections:

 Input/ Output Section: The input section or input module consists of devices
like sensors, switches and many other real world input sources. The input from
the sources is connected to the PLC through the input connector rails. The
output section or output module can be a motor or a solenoid or a lamp or a
heater, whose functioning is controlled by varying the input signals.
 CPU or Central Processing Unit: It is the brain of the PLC. It can be a
hexagonal or an octal microprocessor. It carries out all the processing related
to the input signals in order to control the output signals another liquid on the
control program.
 Programming Device: It is the platform where the program or the control logic
is written. It can be a handheld device or a laptop or a computer itself.
 Power Supply: It generally works on a power supply of about 24 V, used to
power input and output devices.
 Memory: The memory is divided into two parts- The data memory and the
program memory. The program information or the control logic is stored in
the user memory or the program memory from where the CPU fetches the
program instructions. The input and output signals and the timer and counter
signals are stored in the input and output external image memory respectively.

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

industrial digital computer which has been ruggedised and 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.

They were first developed in the automobile industry to provide flexible,

ruggedised and easily programmable controllers to replace hard-wired relays and
timers. Since then they have been widely adopted as high-reliability automation
controllers suitable for harsh environments. A PLC is an example of a "hard" real-
time system since output results must be produced in response to input conditions
within a limited time, otherwise unintended operation will result.

3.7 PLC SPECIFICATIONS:

Fig 3.7 PLC HARDWARE

Description
 Input Supply:24 vlt
 Logic Software: RS LOGIX500
 SMPS: 230v AC input 24v DC
 Manufacturer: ALLEN BRADLEY
 PLC Black: Input
 PLC Red:Output
 Inductive Sensor: 3-24v

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3.8 How PLC Works?

A programmable logic conroller is a specialized computer used to control machines
and processes. It therefore shares a common terms with typical PC’s like central
processing uit, memory, software and communication. Unlike a personal computer
though the PLC is designed to survive in rugged industrial atmosphere and to be very
flexible in how it interfaces with inputs and outputs to the real world.
The componenents that make PLC work can be divided into three areas:
 The power supply and rack.
 The central processing unit.
 The I/O section.

 The Power Supply and Rack

The rack is the component that holds everything together. Depending on the
needs of the control system it can be ordered in different sizes to hold more
modules. Like a human spine the rack has a backplane at the rear which allows
the cards to communicate with the CPU. The power supply plugs into the rack
as well as the supplies a regulated DC power to other modules that plug into
the rack. The most popular power supplies work with 120 VAC or 24 VDC
sources.
 The CPU
The brain of the whole PLC is the CPU module. This module typically lives in
the slot beside the power supply. Manufacturers offer different types of CPUs
Based on the complexity needed for the system. The CPU consists of a
microprocessor, memory chip and other integrated circuits to control logic,
monitoring and communications. The CPU has different operating modes. In
programming mode it accepts the downloaded logic from a PC. The CPU is
then placed in run mode so that it can execute the program and operate the
process.
 Inputs
Inputs devices can consist of digital or analog devices. A digital input card
handles discrete devices which give a signal that is either on or off such as a
pushbuttons, limit switch, sensors or selector switches. An analog input card

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converts a voltage or current (e.g. a signal that can be anywhere from 0 to

20mA) into a digitally equivalent number that can be understood by the CPU.
pressure transducers, flow meters and thermocouples for temperature
readings.
 Outputs
Output devices can also consist of digital or analog types. A digital output card
either turns a device or off such as lights, LEDs, small motors and relays. An
analog output card will convert a digital number sent by the CPU to it’s real
word voltage or current. Typically outputs signals can range from 0-10 VDC
or 4-20mA and are used to drive flow controllers, pressure regulators and
positive controls.

3.9 ADVANTAGES OF PLC:

 Suitable modular design: Elements of PLC are in Modular form. PLC is

designesd easily using these modules.
 Rugged Construction: It is rugged enough to operate in an industrial
environments.
 Greater Reliability: According to logic in a program, the operations are
performed by it.
 Easy Interfacing: The inputs and outputs modules are provided for
interfacing the input and output field devices to it.
 Reprogrammed easily: It is programmed with a minimum down time.
 Ability to communicate with plant computers, another PLC: It
communicate with data collection system placed in control room or field.
 Relatively inexpensive: Relatively inexpensive then hard wired relay control.
 Easy Maintainence: It is modular systems , hence maintained easily and it
has self diagnostic facility.
 Space Efficient: Todays PLC memory is getting bigger and bigger. This
means that we can generate more and more contacts,coils, timers, sequencers,
counters and so on. We can have thousands of contacts, timers and counters in
a single PLC.

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 Flexible: In the past each different electronics devices control by each

controller. Suppose ten machines required ten controllers, but now only with
one tenth PLC machine can be run with each program.
 Easy Error Connection: If one system will be modified or corrects the
change is only done on the programs contained in computers, in a relatively
short time, after that it downloaded to PLC.
 Operating Speed: PLC operation speed is faster than relay. Speed PLC scan
time if determined by it’s units of mSecs.

3.10. Ladder Programming algorithm –

There are many types of programming languages in Programmable Logic
Controller, PLC. Languages are typically fixed to Ladder Logic (LD), Sequential
Function Block (SFC), Function Block Diagram (FBD) and Structure Text (ST). The
common program language of PLC is ladder diagram [5].

Ladder Logic

Ladder diagram is an automatic control diagram language that developed

during World War II.
Ladder logic is the Primary programming language of programmable logic
controllers. Since the PLC was developed to replace relay logic control systems, it
was only natural that the initial language closely resembles the diagrams used to
document the relay logic. By using this approach, the engineers and technicians using
the early PLCs did not need retraining to understand the program. To introduce ladder
logic programming simple switch circuits are converted to relay logic and then to
PLC ladder logic. Any control task modifications are done by changing the program.
This is why the use of the PLC is preferred to the traditional hard wired circuits in
industrial controls [5].

3.11 INTERFACING OF PLC

The interface card is used between the sensors output and PLC for interfacing
purpose. In this system card used is opto-coupler. When the input is detected by the
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sensor then a current limiting resistor is used for reducing the current and drops the
voltage for a certain limit. When sensors provide output then a resistor is used in
series with the opto-coupler [4].
Acy M. Kottalil et al in his Paper automatic railway gate control shows a procedure to
open and close the railway crossing according to condition of the sensors which sense
presence or absence of train. These types of gates can be employed in an unmanned
level crossing where the probability of accidents is higher and reliable and flexible
operation is required. Since, the operation is automatic; error due to manual operation
is prevented with the help of Inductive sensors .The arrival and leaving of the train is
monitored and the gate is operated accordingly. For controlling the Gate servo motor
is used. A servo is a mechanical motorized device that can be instructed to move the
output shaft attached to a servo wheel or arm to a specific position. Inside the servo
box there is a dc motor mechanically linked to a position feedback potentiometer,
gearbox, electronic feedback control loop circuitry and a motor drive electronic circuit
as shown in fig.2

FIG 3.11 SERVO COMPONENT

Servos are controlled by sending them a pulse of variable width. The control wire is
used to send this pulse which controls the movement of a motor. It is important to
note that different servo motor will have different constraints on their rotation but
they all have a neutral position, and that position is always approximately around 1.5
milliseconds. The angle is determined by the duration of a pulse that is given to the
control wire [1]. When a pulse is given to a servo motor that is less than 1.5 ms then
servo rotates to a position and holds its output shaft some number of degrees anti-
clockwise from the neutral point. When the pulse is larger than 1.5 ms then opposite

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occurs. Generally the minimum pulse width will be approximately about 1 m wide
and the maximum pulse width will be 2 ms wide. This way servo motor rotates
maximum 180 degree. It does not rotate continuously [6]. This motor is best for our
application to operate road barriers present on the either side of the bridge [1].

3.12 SYSTEM COMPONENTS & DESIGN

The system deals with controlling the process of opening and closing of bridge
automatically with the help of PLC. The system is design by using sensors such as
Inductive, DC motor & Servo motor.

3.12.1. INDUCTIVE SENSOR

A Inductive sensor is a sensor able to detect the presence of nearby objects
without any physical contact. A Inductive sensor often emits an electromagnetic field
or a beam of electromagnetic radiation (infrared for instance), and looks for changes
in the field or return signal. The object being sensed is often referred to as the
inductive sensor's target. An inductive sensor always requires a metal target. In this
model two inductive sensors are used for detecting arrival and leaving of ship.
Inductive sensors exploit the interaction of metallic conductors with their alternating
electromagnetic fields. Eddy currents are induced in the conductor. They draw energy
from the field, reducing the oscillation amplitude. Inductive sensors evaluate this
change. The area through which the high-frequency sensor field enters space is
described as the active area. It roughly corresponds to the area of the pot core cap.
Inductive sensors are suitable for controlling and monitoring machine processes, and
for providing signals in counting tasks where metals are involved. In particular, they
are characterised by their immunity to vibrations, impacts, dust and dampness, and
operate with extreme precision.

FIG 3.12.1. INDUCTIVE SENSOR

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3.12.2. 24V RELAY

A relay is an electrically operated switch. Many relays use an electromagnet

to mechanically operate a switch, but other operating principles are also used, such as
solid-state relays. The first relays were used in long distance telegraph circuits as
amplifiers: they repeated the signal coming in from one circuit and re-transmitted it
on another circuit. Relays were used extensively in telephone exchanges and early
computers to perform logical operations. In this project we are using six 24V relays to
perform our operation.

FIG 3.12.2. 24V RELAY

3.12.3 24V POWER SUPPLY

A power supply is an electronic device that supplies electric energy to an

electrical load. The primary function of a power supply is to convert one form of
electrical energy to another. As a result, power supplies are sometimes referred to as
electric power converters. Some power supplies are discrete, stand-alone devices,
whereas others are built into larger devices along with their loads. In this project 24V
power supply is used for carrying out all the operations.

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Fig 3.12.3. 24V POWER SUPPLY

3.12.4. DC MOTOR

This DC or direct current motor works on the principal, when a current

carrying conductor is placed in a magnetic field, it experiences a torque and has a
tendency to move.
This is known as motoring action. If the direction of current in the wire is reversed,
the direction of rotation also reverses. When magnetic field and electric field interact
they produce a mechanical force, and based on that the working principle of DC
motor is established.

A DC motor is any of a class of rotary electrical machines that converts direct

current electrical energy into mechanical energy. The most common types rely on the
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forces produced by magnetic fields. Nearly all types of DC motors have some internal
mechanism, either electromechanical or electronic; to periodically change the
direction of current flow in part of the motor. DC motors were the first type widely
used, since they could be powered from existing direct-current lighting power
distribution systems. A DC motor's speed can be controlled over a wide range, using
either a variable supply voltage or by changing the strength of current in its field
windings. Small DC motors are used in tools, toys, and appliances. The universal
motor can operate on direct current but is a lightweight motor used for portable power
tools and appliances. Larger DC motors are used in propulsion of electric vehicles,
elevator and hoists, or in drives for steel rolling mills. The advent of power electronics
has made replacement of DC motors with AC motors possible in many applications.
In this project two DC motor are used in the either side of the bridge for
controlling the barricades present on the bridge for controlling the traffic when the
ship arrives.

Fig 3.12.4 12V DC MOTOR

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3.12.5. SERVO MOTOR

Servo motor is used to opening and closing of bridge according to signal of

inductive sensor. Servo motor basically works on pulse of variable width. Generally
the width of the pulse ranges from 1 ms to 2 ms, hence servo motor rotates maximum
up to 180º and it cannot rotate continuously like DC motor [6]. The servo motor is
most commonly used for high technology devices in the industrial application like
automation technology. It is a self contained electrical device, that rotate parts of a
machine with high efficiency and great precision. The output shaft of this motor can
be moved to a particular angle. Servo motors are mainly used in home electronics,
toys, cars, airplanes, etc.

Fig 3.12.5 SERVO MOTOR

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3.12.6 SIGNAL POLE

Signal pole is used to indicate vehicle to stop. When ship would be detected,
red light would be ON to indicate vehicle to stop because bridge will be about to open
and when will ship pass through bridge, so after that bridge is closed then Green lights
is turned ON again.

Fig 3.12.6. SIGNAL POLE

3.7 TABLE OF COMPONENTS

Sr.No. COMPONENTS RANGE/TYPE

1. INDUCTIVE SENSOR +3V-24VDC(PNP)
2. DC MOTOR +24V
3. RELAY +24V
4. SERVO MOTOR 1mm-3mm

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CHAPTER 4

4.1 PROTOTYPE MODEL OF PROJECT

The Prototyping Model is a method of system development in which a prototype is

built and tested. Or we can also say this is an early approximation of how actual
system would work. Fig. 4 shows the model of Bridge. Here model of bridge is made
from wood and here bridge will be open or close with the help of strings.

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Fig 4.1: PROTOTYPE OF MODEL.

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Fig 4.1.2: INDUCTIVE SENSOR

Fig shows simple Inductive TX-RX . This circuit checks the condition of bridge
weather it is opened or not.

4.2 FLOW CHART:

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4.3 LADDER DIAGRAM

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FIG 4.3. LADDER DIAGRAM

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4.4 RESULT AND ANALYSIS:

In this project, system is designed to control the process of opening
and closing bridge automatically when ship will be detected. Here Ship would
be detected at 5cm distance by Inductive Receiver. As soon as PLC gets high
to low signal it drives the servo motor to close road barriers and signal
changes from green to red. Then after PLC drives DC motor to open the
bridge. As PLC gets signal from Inductive sensor it would stop DC motor.
Hence the bridge is opened. As soon as ship passes through the bridge it’ll
detect by sensor at other side of the bridge and it will send high to low signal
to PLC.
PLC first drives DC motor in reverse direction until bridge is totally closed.
Then road barrier will be opened and signal changes from red to green.
The process has been made automatic so it can reduce the need of manpower
and it would result into flexible operation. Installation of system is initially
costly but overall performance proves it to be cost-effective.

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CHAPTER 5

ADVANTAGES:
 REDUCES MANPOWER: With the help of automation we can open and
close the bridge. So it reduces the human efforts to lift the barricade and also
to open and close the bridge
 FLEXIBLE OPERATION: In the past each different electronics devices
control by each controller. Suppose ten machines required ten controllers, but
now only with one tenth PLC machine can be run with each program.
 ENSURES SAFETY: Automation reduces the manpower required to move
huge pulleys and different machinery which may cause injuries to humans.

DISADVNTAGES:
 HIGH COST: Installation of system is initially costly but overall
performance proves it to be cost-effective.

APPLICATIONS:
 PLC based draw bridge is used to ease the transportation via water paths.

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CHAPTER 6

6.1 CONCLUSION :

In this project, we presenting the designing of a PLC based control system for
automatic opening and closing of bridge. The automated process may efficiently
reduces the man power required for the process and may also increases the efficiency.
The use of PLC for controlling action of the system may effectively leads to
intelligent system which requires less time compared to human and this system also
may ensures safety.

6.2 FUTURE SCOPE:

 SCADA (supervisory control and data acquisition) implementation

can be done for monitoring all the process.
 CCTV camera can be utilized for more accuracy in the ship
detection.
 This process can be implemented between twin cities divided by
river, lagoons making it as effective measure of transport.

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CHAPTER 7
REFERENCES:

[1]. Bhavin V. Mangukiya, Sandip B. Kheni, Kaushik B. Desai, Prof. Kaushika Patel,
Bridge Control Automation using PLC IJSRD -
International Journal for Scientific Research & Development| Vol. 4, Issue 02, 2016
[2]. http://www.madehow.com/Volume-6/Draw-Bridge.html
[3]. http://www.madehow.com/images/hpm_0000_0006_0_img0046.jpg
[4]. Muhammad Arshad Khattak, „‟PLC based intelligent traffic control system‟‟, International
Journal of Electrical & Computer Sciences IJECSIJENS
Vol: 11 No: 06
[5]. Sandar Htay , Su Su Yi Mon ,“Implementation of PLC Based Elevator Control System”, ISSN
2277-1956/V3N2-91-100
[6]. Acy M. Kottalil, Abhijith S, Ajmal M M, Abhilash L J.,Ajith Babu,” Automatic railway gate
control system.‟‟ International Journal of
Advanced Research in Electrical, Electronics and Instrumentation Engineering, Vol. 3, Issue 2,
February 2014.
IARJSET ISSN (Online) 2393-8021

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