DESIGN AND DEVELOPEMENT OF A CONTROL SYSTEM SIMULATOR USING PROGRAMMABLE LOGIC CONTROLLER (PLC)

By TANVEER AHMED & MD ASRAFUL GONI

This project report submitted to the department of Electrical and Electronic Engineering in partial fulfillment of the requirements for the degree of Bachelor of Science in Electrical and Electronic Engineering

DEPARTMENT OF ELECTRICAL AND ELECTRONIC ENGINEERING

CHITTAGONG UNIVERSITY OF ENGINEERING AND TECHNOLOGY

JANUARY, 2006

DEPARTMENT OF ELECTRICAL AND ELECTRONIC ENGINEERING

CHITTAGONG UNIVERSITY OF ENGINEERING AND TECHNOLOGY

CERTIFICATION OF PROJECT TITLE

Design and development of a control system simulator using Programmable Logic Controller (PLC)
Submitted to the Department of Electrical and Electronic Engineering, CUET By

TANVEER AHMED & MD ASRAFUL GONI

0002023 0002053

Accepted as satisfactory for partial fulfillment for the degree of Bachelor of Science in Electrical and Electronic Engineering

Under the supervision of

--------------------------------------------( Prof. Dr. M. Shamsul Alam) Dean Faculty of Electrical and Computer Engineering
Chittagong University of Engineering and Technology

DEDICATION

To our respectable teacher Prof. Dr. M. Shamsul Alam His inspiration, wise counsel and helpful support has made this project possible

ACKNOWLEDGEMENT
There is a man who loves the students, thinking for their future, advice them for their decision making, helps them for building up their academic carrier, the man who is the teacher for the curious students, helper for the weak students and idol for the brave and hard working students is our respectable teacher Prof. Dr. M Shamsul Alam .

We are overwhelmed with pleasure and proud to express our heart-felt gratitude and thanks to our supervisor who inspired us to take up the initiative of this project work and for his suggestion, wise counsel, constructive criticism and continuous encouragement during our project work.

We also grateful to Electrical and Electronic Engineering Department and Institute of Energy Technology, CUET for fulfilling our ever-increasing demands of various facilities.

We also convey our cordial thanks to the officials of Training institute of Chemical Industries (TICI) and various Industries we visited for their helpful and teaching mentality for the fulfillment of this project.

January, 2006

Author

ABSTRACT

Control can be defined as keeping a physical variable (pressure, temperature, level, flow etc.) as constant as possible by measuring instantaneous value of physical variable, comparing it with the desired value and using the difference to make a correction which reduces this difference. A Control System is the electronic or electromagnetic equipment needed to control a particular process. It may include everything from a process control computer, if one is used, to the factory computer, down through the PCs (and there may be many of them networked together) and then on down through the network to the control components: the switches, stepping motors, solenoids, and sensors, which monitor and control the mechanical operations. Programmable Logic Controller (PLC) are used in Industries from last twenty yeas. This is a very flexible controlling device, can be used in every type of industries for the automation. An era was started after the invention of microprocessor; to design develops microprocessor-based system for automation of the machines. Similar is in the case of PLC, when it was discovered in an automobile industry. PLC which has a fixed hardware, manufactured by the several manufacture worldwide, can be in-corporate in any mechanical and electrical system by writing suitable programs, as per the need of the user of machine or system. Always there is a need for the study of available books on PLC and its operating manuals, provided by the manufacture for proper working with the PLC. To fulfill this need this control panel simulator will help the students to be a PLC user.

CONTENTS
CHAPTER TITLE PAGE

I 1.1 1.2 1.3 1.4 1.4.1 1.4.1.1 1.4.1.2 1.4.2 1.4.2.1 1.4.2.2 1.5 1.6 1.7 1.7.1 1.7.2 1.7.3 1.7.4 1.7.5 1.8 1.8.1 1.8.2 1.8.3

Title of the project Certificate of approval Dedication Acknowledgement Abstract Contents List of Figures List of table INTRODUCTION

Definition of control
What is a Control System? Types of control Components of conventional sequential system Switch Momentary contact switch Maintained contact switch

Relay Components of Relays Mode of Operation Sequential Control Advantages of Automatic Control General concept Programming Language and Technique Real-Time operation/ orientation Environmental Consideration Maintenance and Trouble Shooting Features and Advantages of PLC Architecture Power Supply Unit Central processing unit (CPU) Input Modules

1.8.3.1 1.8.4 1.8.5 1.8.6 1.8.7 1.8.8 1.8.9 II 2.1 2.2 2.3 2.4 2.4.1 2.4.2 2.5 2.6 2.6.1 2.6.2 2.6.3 2.6.4 2.6.5 2.6.6 2.6.7 2.6.8 III 3.1 3.1.1 3.1.2

Types of input components Output Modules

Types of output components

Programming Device Mechanical design of PLC system Signal processing in PLC Input/output processing DESIGN APPROACH Simulation panel components Steel frame Steel frame with board Materials required
Required steel angle

Required amount of other equipments Block diagram of the overall simulation pane Components description Programmable Logic Controller RS-232C Adapter (Interfacing unit) Sensor panel
Load panel Rare panel Floor panel

Relays Relay base DEVELOPMENT APPROACH Panel layout Input ports Output ports

3.1.3 3.1.4 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.3 IV 4.1 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.3 4.4

Sensor panel Load panel Wiring PLC with panels Connection PLC with sensor panel Connection PLC with relay panel Connection relay contact with load panel Connection with PC PLC connection with host link RS-232 connector configuration Developed Simulation panel PERFORMANCE CHECK Coasting Result ROBOT control system Sequence of operation by drawing the flowchart Writing the program Input Output Description Conclusion Discussion REFERENCE

List of Figure

Figure 1.1: Block diagram of control loop Figure 1.2: A typical Control System Figure 1.3: Symbolic representation of different type of sequential switches Figure 1.4: Basic relay configuration Figure 1.5: Block Diagram of a PLC Figure 1.6: Input device (module) Figure 1.7: DC input unit Figure 1.8: Ac input unit Figure 1.9: Triac output unit Figure 1.10: Transistor output unit Figure 2.1: Steel frame dimension Figure 2.2: Steel frame with board Figure 2.3: Block diagram of simulation panel Figure 2.4: PLC and RS-232C Adapter Figure 2.5: Load panel with eight lamps Figure 2.6: Load panel with eight lamps Figure 2.7: Rare panel with relay which connects the load. Figure 2.8: Rare panel with power supply units Figure 2.9: Relay internal configuration Figure 2.10: Relay base configuration Figure 3.1: Input port layout Figure 3.2: Output ports layout Figure 3.3: Sensor panel configuration Figure 3.4: Load panel configuration Figure 3.5: Connection PLC with sensor panel Figure 3.6: Connection PLC with sensor panel Figure 3.7: Connection PLC with relay panel Figure 3.8: PLC connected with PC through RS-232 cable

Figure 3.9: Connection process with other PLC Figure 3.10: Outlay of RS-232 connector port Figure 3.11: RS-232 connector configuration Figure 3.12: Developed Simulation panel Figure 4.1: Robot control system Figure 4.2: Flow chart of sequence of operation

List of Table Table 3.1: Input terminal address Table 3.2: Output terminal address Table 3.3: Terminal no. Address Table 3.4: Output terminal address Table 4.1: Input Output Description

Chapter 01

INTRODUCTION

1.1 Definition of control:

Control can be defined as keeping a physical variable (pressure, temperature, level, flow etc.) as constant as possible by measuring instantaneous value of physical variable, comparing it with the desired value and using the difference to make a correction which reduces this difference.

Disturbance Correcting unit Correction Process Variable Measured Variable Measuring system

Outline

Deviation

Control Element

Differential Element Controll Desired

Figure 1.1: Block diagram of control loop

1.2 What is a Control System?

A Control System is the electronic equipment needed to control a particular process. It may include everything from a process control computer, if one is used, to the factory computer, down through the PCs (and there may be many of them networked together)

and then on down through the network to the control components: the switches, stepping motors, solenoids, and sensors, which monitor and control the mechanical operations.

Figure 1.2: A Control System can involve very large applications where many different models of PC are networked together or it could be an application as small as a single PC controlling a single output device

1.3 Types of control

Manual Control: When the operator to operate the process to a desired condition carries out the corrective action then it is manual control. Automatic Control: When the instruments carry out the corrective action then it is automatic control.

1.4 Components of conventional sequential system

The main components are switches, relays, timers, and counters.

1.4.1 Switch
The purpose of switch is to close or open the electrical circuit to a load. Mainly switches are of two types: 1. Momentary contact switch 2. Maintained contact switch

1.4.1.1 Momentary contact switch

When the actuated power is applied to the switch it changes its position, but if the power is withdrawn the switching position will be returned to the previous position, this type of switching is called the momentary contact switching. Example: Push button switch, limit switch, non-latched relay, pressure switch etc.

NO relay contact

NC relay contact

Start switch

Stop switch

NO relay contact

NC relay contact

Auto/Manual switch

Figure 1.3: Symbolic representation of different type of sequential switches

1.4.1.2 Maintained contact switch

When the actuated power is applied to the switch it changes its position, but if the power is withdrawn the switching position will be unchanged, this type of switching is called the maintained contact switching. Example: Normal ON-OFF switch, change over switch, latched relay.

1.4.2 Relay
Relays are intended to open or close several contact paths simultaneously when a coilactuated switch is actuated. Relays make possible, using a low level of control energy to switch high power levels and actuate several contacts at the same time.

Figure 1.4: Basic relay configuration

1.4.2.1 Components of Relays

1. Coil 2. Iron core 3. Armature 4. Contact piece with contacts 5. Spring

1.4.2.2 Mode of Operation

Relays are spring return switches which are switched ON or held in the ON position by Electromagnetic means. When a solenoid coil is de-energized, the spring 5 pulls the armature 3 away from the iron core as shown in fig 1.1. The various contacts are open or close depending on their type. When a solenoid coil is energized the armature 3 is pulled towards the iron core in fig 1.2. At the same time the contact positioned one behind the other is open or close, depending on their type.

1.5 Sequential Control

The manner of operating a machine or plant by feeding the steps into a particular order for control and safe operation is called sequential control. Sequential control is normally done digitally and arranged sequentially. It improves the quality of control as well as safety of the machine and the plant. In the conventional control system sequential logic operation, process automation and safety is done by permanently connecting the electrical/electronic, pneumatic or hydraulic relays, timers, counters etc. On the other hand, in the computerized control system automation and sequential logic the Programmable Logic Controller (PLC) does operation.

1.6 Advantages of Automatic Control

Increased production Improved quality Greater product uniformity Saving in raw material Saving in energy Saving in manpower

1.7 General concept

Programmable logic controller was first designed by the engineer of general Motor Corporation in 1968 to eliminate the costly assembly line relay logic circuit, during model change over. Presently more then 50 companies are manufacturing PLCs.

A programmable logic controller is a 'digital operating system ' designed for use in an industrial environment, which uses a programmable memory for its internal operation of user-orientated instructions and for implementing specific function such as logic, sequencing, timing, counting and arithmetic. PLC controls digital and analog inputs and outputs in the various types of machines or processes. PLC were developed to offer a flexible alternative to conventional electrical circuit relay based control, built up using discrete devices.

The terminology and other concept used to describe the operation of PLC are based on conventional relay control terminology. The relationship is such that inputs ate referred to as contacts and outputs are referred to as auxiliary relays. The International Electro Technical Commission (IEC) advocates six (6)-programming methods for PLC. Of theses six, the predominant programming method used by all mainstream PLC system is the ladder diagram method.

1.7.1 Programming Language and Technique

PLC languages are designed to emulate the popular relay ladder diagram format. This format is easily readable and understood worldwide by maintenance as well by engineers.

1.7.2 Real-Time operation/ orientation

The PLC is designed to operate in a real-time control environment. Most PLC have internal clock and watching timers, built into their operation to ensure that some functional operation does not send the central processor into the' Weeds. The first

priority if the CPU is to scan the I/O for status, to make sequential control decisions, to implement those decisions and to repeat this al within the allotted scan time.

1.7.3 Environmental Consideration

PLC are designed to operate near the equipment they are meant to control. This means that they function in hot, humid noisy, and dusty industrial environments. Typically, PLC can be operated from 0o to 70 o C temperature range. Also 0% to 90% non-condensing humid atmosphere is suitable for the PLC. In addition, they have electrical noise immunities comparable with those required in military specifications.

1.7.4 Maintenance and Trouble Shooting

The PLC is maintainable by the plant electronics or Instrument technicians. It would be in self-diagnostics to allow for easy trouble shooting build and repair of problems. Most PLC component is modular and simple to isolate, remove-and-replace and diagnostic techniques can easily be implemented.

1.7.5 Features and Advantages of PLC

Easy to program Does not suffer from fatigue problem Cost effective Can be checked without field devices Can perform complex logic operation Can interface with computer Easy maintenance Faster system response Compact in construction Monitoring facility available High reliability

On line ON OFF facility of inputs and outputs

1.8 Architecture
The internal hardware and software configuration of PLC is referred to as its architecture. Being a microprocessor based system the design on the following building blocks.

1. Central processing unit. 2. Input devices (Modules) 3. Output devices (Modules) 4. Power supply 5. Input components 6. Output components 7. Memory 8. Programming unit

CPU

Process Program Memory Timer Counter Flag input image tables

Process input image tables

RAM

R OM

Processor

Memory sub module Serial port

ALU

I/O bus Digital Modules - Input modules - Output modules Analog Modules - Input modules - Output modules I/O modules

Figure 1.5: Block Diagram of a PLC

1.8.1 Power Supply Unit

The power supply unit is needed to convert the main AC voltage to the DC voltage (5V) necessary for the processor and the circuit in the input and output interference modules.

1.8.2 Central processing unit (CPU)

The CPU is the microprocessor-based system that replaces the relays, timer, counter etc. The CPU accepts (reads) input data from various sensing devices, executes the arithmetic and/or logic functions in accordance with the stored user program and produce outputs. These outputs are sent to the output circuit.

The memory module is a major part of CPU. There are several memory elements in a PLC

User Program (RAM): Generally, ' PLC uses the CMOS-RAM with battery support for user program memory.

Process Image Tables (RAM): Signal states of input and output modules are stored in the CPU in "process image tables". Values of timers, counters and other internal devices are also stored here.

Timers, Counters and Flags (RAM): The CPU has timers, counters and flag available internally that the control program can use. The program can set delete, start and stop the timers and counters. The time and count values are stored in reserved areas of the RAM memory.

Operating system (ROM): The operating system is permanently stored in the ROM. The system program determines how the user program is executed, how inputs and outputs are managed and how the memory is divided. The manufacturer places information in the ROM there.

Memory sub module (EPROMI EEPROM): The User Program can be stored in a memory sub module. The sub module may be EPROM or EEPROM. The EPROM needs an ultraviolet source to entire erase of the program. The EEPROM does not require any ultraviolet source. It offers the same programming facility as does RAM. It provides permanent storage of the program but can be easily changed using standard programming device. It is a back up of the user program

1.8.3 Input Modules

Inputs are defined as real world signals giving the controller real time status of process variables. These signals can be analog or digital, low or high frequency.

Electrical optical isolation

S1

Filter

Electrical optical isolation

S2

Filter

Electrical optical isolation

S8

Filter

Figure 1.6: Input device (module)

A PLC can handle analog as well as digital signal. 4 - 20 mA dc, 0 - 20 mA dc, 10 - 50 mA dc, 1 - 5 V dc etc is analog signals. Digital signals are the combination of a certain number of electrical pulses. The magnitudes of these pulses are 5 V dc normally. In industries most of the digital signals are one bit pulse; either a switch is OPEN or CLOSED. We have discussed here only the Digital Input & Digital Output Modules.

Digital Input Modules: Digital Input interface modules accept signals from the machines or process devices (120 V ac or 24 V dc) and convert them into signals (5 V dc) that can be used by the microprocessor.

Figure 1.7: DC input unit

Figure 1.8: AC input unit

1.8.3.1 Types of input components

On the machine side the different Input components used. These input components are connected to input devices (modules) of the PLC for feeding input signal to the CPU of PLC through Input module. Typically, these are presented to the programmable controller as a varying voltage, current or resistance value. Signals from the thermocouples (TC's) and resistance temperature detector (RTD's) are common examples of analog signals. Some flow meters and strain gauges provide variable frequency signals, while push buttons, limit switches or even electromechanical relay contacts are familiar examples of digital contact closure type signals. Some of the input components are:

1. Toggle switches 2. Limit switches 3. Centrifugal switches 4. Level switches 5. Pressure switches 6. Push button switches 7. Selector switches

8. Temperature switches 9. Flow switches 10. Proximity switches, etc.

1.8.4 Output Modules

Output interface modules convert controller signals (5 V dc) into external signals (120 V ac) used to control the machine or process. The output module of a PLC acts as a switch to supply power from the user supply to operate the load. Output devices such as small motors, motor starters, solenoid valves and indicator lights are hardwired to the terminals on the output modules. The output switching devices most often used to switch power to the loads are:

1. Relay for ac or dc loads 2. Triac for ac loads only 3. Transistors for dc loads only

Figure 1.9: Triac output unit

Figure 1.10: Transistor output unit

1.8.5 Types of output components

There are three common categories of outputs; they are discrete, register and analog. Discrete outputs can be pilot lights, solenoid valves or enunciator windows. Register output can drive panel meters or displays, analog output can drive signal to variable speed drives or to input converters and turns the control valves. Further more, the different output components are :

1. Motors 2. Relays 3. Meters 4. Enunciators 5. Coils 6. Pilot lights 7. Bells 8. Alarms, etc.

1.8.6 Programming Device

Programs are entered into the PLC memory using a programming device that is usually not permanently connected to a particular PLC and can be moved from one PLC to the next without disturbing the operations. It allows the user to enter, edit and monitor programs by connecting into the processor unit allowing access to the user memory. Programming device can be a hand-held device or a personal computer. A personal computer with appropriate software can act as a -program terminal. When the program has been designed on the programming device and is ready, it is transferred to the memory unit of PLC. PLC can handle one program in memory at a time can handle of input and output terminals: Each terminal on input and output modules is assigned a unique address number. This address is used by the microprocessor to identify the location of the device in order to monitor or control it. These addresses can be represented in decimal, octal or hexadecimal terms depending upon the number system used by PLC.

1.8.7 Mechanical design of PLC system

There are two common types of Mechanical design for PLC system. These are: Integral type Modular type

The integral type is commonly used for small process and is supplied with integral package complete with power supply, processor, memory and input/output units. The modular type consists of separate modules for power supply, processor, inputs and outputs. So, in modular type it is easy to expand the number of input/output connections by just adding more input/output modules or to expand the memory by adding more memory units.

1.8.8 Signal processing in PLC

The CPU of a PLC controls and supervises all operations with in the PLC. It carries out programmed instructions stored in the memory. A bus system carries information to and from the CPU, memory and I/O unit under the control of CPU. The information with in the PLC is carried by digital signal. The internal path along which the signal flows is called bus.

The system has four buses. The CPU uses the data bus or sending data between the constituent elements, the address bus to send the addresses of location for accessing stored data and the control bus for signals relating to internal control actions. The

system bus is used for communications between the input/output ports and input/output unit.

In general, the CPU (microprocessor) has: An arithmetic and logic (ALU) unit: It is responsible for data manipulation carrying out arithmetic operations of addition and subtraction and logic operations of AND, OR, NOT and EXCLUSIVE-OR.

Memory, termed registers, located with in the microprocessor and used to store information temporarily involved in program execution.

A control unit, which contains a program counter, registers which points to the next instruction to be fetched from memory. The CPU has a serial port, and we can connect a programmer, operator panel and

1.8.9 Input/output processing

A PLC may have hundred input/output points. Since the CPU can deal with only one instruction at a time during program execution, the status of each input point must be examined individually. For rapid program execution, input and output updating may be carried out at one particular point in the program. Each input and output has a cell in the I/O RAM. During I/O copying, the CPU scans all the inputs in the I/O unit and copies their status into the I/O RAM cells. This happens at the start/end of each program cycle. As the program is executed, the stored input data is read one location at a time from the IIO RAM. Logic operations are performed on the input data; and the resulting output signals are stored in the output section of the I/O RAM. Then at the end of each program cycle the I/O copying routine transfers all output signals from the I/O RAM to the corresponding output channel. These output stages are latched and they retain their status until they are updated by the next I/O routine. The updating sequence is thus follows:

Scan all the inputs and copy into RAM Fetch and execute all program instructions in sequence Copying output instruction to .RAM Update all outputs Repeat the sequence. `

Chapter 02 Design approach

2.1 Simulation panel components

01. Programmable Logic Controller (PLC) 02. Interface Unit (CPM1-CIF01) 03. Power supply-1 for PLC input & output module (omron 24V DC) 04. Power supply-2 for Lamps supply (24V DC) 05. 24V DC Relay (omron MY2N) 06. Two contact relay base 07. Push button switch 08. Toggle switch 09. 24V DC Flashing lamps 10. Banana socket and plug 11. Cable socket 12. Channels 13. Steel frame 14. Cables 15. A Personal Computer (PC) with window 98 and above version 16. SYSWIN 3.4 programming software dedicated to omron PLC only 17. Others.

2.2 Steel frame

Figure 2.1: Steel frame dimension

2.3 Steel frame with board

Figure 2.2: Steel frame with board

2.4 Materials required

2.4.1 Required steel angle

Vertical legs = 4 Horizontal arms = 8 Vertical arms = 2 Inclined arms = 8

Vertical legs

= (4*5) feet = 40 feet

Horizontal arms = (8*2.5) feet = 20 feet Inclined arms = (8*1) feet = 8 feet Vertical arms = (2*1) feet = 2 feet Total angle required = (40+20+8+2) feet = 70 feet

2.4.2 Required amount of other equipments

1. Programmable Logic Controller (PLC) --------------------01 piece 2. Interface Unit---------------------------------------------------01 piece 3. Power supply---------------------------------------------------02 piece 4. 24V DC Relay--------------------------------------------------08 piece 5. Two contact relay base ---------------------------------------08 piece 6. Push button switch --------------------------------------------06 piece 7. Toggle switch --------------------------------------------------06 piece 8. 24V DC Flashing lamps --------------------------------------08 piece 9. Banana socket and plug --------------------------------------56 piece

10. Cable socket ----------------------------------------------------200 piece 11. Channels --------------------------------------------------------02 piece 12. Cables -----------------------------------------------------------50 yard

2.5 Block diagram of the overall simulation panel

Personal computer

Interfacing Unit

Sensor panel

Input Module P-

CPU - L-

Output Module -C

Load panel

24V DC Power Supply for PLC

24V DC Power Supply for Lamps

Power Circuit Breaker

Power mains

Figure 2.3: Block diagram of simulation panel

2.6 Components description

Programmable Logic Controller (PLC), interface Unit, relay, switches etc. are used in this system. In this section brief description of these important parts are described.

Figure 2.4: PLC and RS-232C Adapter

2.6.1 Programmable Logic Controller

Model: CPM1A-20CDR-A-V1 Manufacturer: omron I/O points: 20 (12 input and 8 output) Supply voltage: 100-240V AC, 50/60 Hz Power consumption: 30VA max External power supply voltage: 24V DC External power supply output capacity: 200mA Ambient temperature: (0-55) o C.

Programming language: Ladder diagram Types of instructions: 14(Basic), 135(Special) Execution time: (0.72-16.2) micro sec. Program capacity: 2048 words

2.6.2 RS-232C Adapter (Interfacing unit)

Model: CPM1-CIF01 Manufacturer: omron Power supply: CPU of PC supplies power Power consumption: 0.3A max Transmission speed: 38.4 Kbps max

2.6.3 Sensor panel

In this panel there are twelve switches (six are push button type and another six is maintain contact type), which are used as sensors that used in practical system and also twenty-four banana sockets in two rows.

Figure 2.5: Load panel with eight lamps.

2.6.4 Load panel

In this panel there is lamps of 24V DC which are used as loads that used in practical system and also thirty-two banana socket in four rows.

Figure 2.6: Load panel with eight lamps

2.6.5 Rare panel

There are eight 24V DC relay used in this panel that will help to use various ratings load.

Figure 2.7: Rare panel with relay which connects the load.

2.6.6 Floor panel

There is two-power supply and a connection bus in this panel, one power supply is for PLC output module and another for loads.

Figure 2.8: Rare panel with power supply units

2.6.7 Relays
Model: MY2N Manufacturer: omron Supply voltage: 24V DC No. of contacts: There are eight pin in a relay with two contacts set. Contact 1(8 and 12 -- normally open, 5 and 9 -- normally open) Contact 2(1 and 9 -- normally closed, 4 and 12 -- normally closed) Coil: Pin 13 and 14.

Figure 2.9: Relay internal configuration

2.6.8 Relay base

There are eight pins same as relay, which is used for relay setup.

Figure 2.10: Relay base configuration

Chapter 03 Development approach

3.1 Panel layout
The input port. output port ,sensor panel, load panel are shown in this section.

3.1.1 Input ports

Figure 3.1: Input port layout

Table 3.1: Input terminal address

Terminal No.

Address

00 01 02 03 04 05 06 07 08 09 10 11

000.00 000.01 000.02 000.03 000.04 000.05 000.06 000.07 000.08 000.09 000.10 000.11

3.1.2 Output ports

Figure 3.2: Output ports layout

Table 3.2: Output terminal address

Output terminal no.

Address

00 01 02 03 04 05 06 07

010.00 010.01 010.02 010.03 010.04 010.05 010.06 010.07

3.1.3 Sensor panel

Various switches accumulated in sensor panel are connected with PLC input module.

Figure 3.3: Sensor panel configuration The terminal number used in PLC input module is addressed according to the table shown below.

Table 3.3: Terminal no. Address Terminal No. Addresses

00 01 02 03 04 05 06 07

000.00 000.01 000.02 000.03 000.04 000.05 000.06 000.07

08 09 10 11

000.08 000.09 000.10 000.11

3.1.4 Load panel

Lamps of 24V DC are accumulated in load panel those are in series with relay contact.

Figure 3.4: Load panel configuration

3.2 Wiring PLC with panels

In this section the total wiring of this simulation panel are shown.

3.2.1 Connection PLC with sensor panel

Figure 3.5: Connection PLC with sensor panel

3.2.2 Connection PLC with relay panel

Figure 3.6: Connection PLC with sensor panel

Table 3.4: Output terminal address

Output terminal no.

Address

00 01 02 03 04 05 06 07

010.00 010.01 010.02 010.03 010.04 010.05 010.06 010.07

3.2.3 Connection relay contact with load panel

Figure 3.7: Connection PLC with relay panel

3.2.4 Connection with PC

Figure 3.8: PLC connected with PC through RS-232 cable

3.2.5 PLC connection with host link

Figure 3.9: Connection process with other PLC

3.2.6 RS-232 connector configuration

Figure 3.10: Outlay of RS-232 connector port

Figure 3.11: RS-232 connector configuration

3.3 Developed Simulation panel

Figure 3.12: Developed Simulation panel

Chapter 04 Performance Check

4.1 Coasting
Programmable logic controller = (20000*1) Tk = 20,000 Tk Interfacing unit = (9000*1) Tk = 9,000 Tk Power supply unit 1 (omron) = (2,500*1) Tk = 2,500 Tk Power supply unit 2 = (750*1) Tk = 750 Tk Steel frame = 1,000 Tk Flashing bulb = (85*8) Tk = 680 Tk Relay = (85*8) Tk = 680 Tk Relay base = (20*8) = 160 Tk Banana socket and plug = (35*56) Tk = 1,960 Tk Ebonite board = (250*4) Tk = 1000 Tk Cable socket = (1.5*200) Tk = 300 Tk Channel = (70*2) Tk = 140 Tk Three cord cable = (25*3) Tk = 75 Tk Normal cable = (7*40) Tk = 280 Tk Three pin plug = (25*1) Tk = 25 Tk RS-232 cable = (60*3) Tk = 180 Tk Male and female port = (90*2) Tk = 180 Tk Nut bolds = 200 Tk Color = 20 Tk Par tax board = 350 Tk Wheel=220 Tk

Total amount = 39,700 Tk

4.2 Result
A practical problem of robot control system simulation testing is done by this panel that shown below.

4.2.1 ROBOT control system

Figure 4.1: Robot control system This kind of robot is seen in many automated factories. As is apparent from the figure, this robot picks up a work being carried on conveyor A, and places it on conveyor B. Although seemingly simple, executing this series of operations with electric devices and circuitry is harder than realized. Looking at the above figure closely will disclose that the robot performs one operation at a time when a given condition is met. Let's analyze these operations and conditions.

1. When the start button is pressed, the robot rotates its arm clockwise. 2. When the robot arm has moved to the position of the work in conveyor A, the arm grasps the work. 3. When the arm has grasped the work, it rotates counterclockwise. 4. When the arm has rotated to the position of conveyor B, it releases the work.

4.2.2 Sequence of operation by drawing the flowchart

NO Start Button SOL 1

Arm rotates clockwise Yes Arm at LS1

NO

Conveyor A on Yes Photo eye sense NO

Conveyor A off Yes NO Is LS3 on

Arm rotates counterclockwise Yes Arm at LS2 NO

SOL 2

Release Workpiece Yes Is Ls3 off Yes NO

Figure 4.2: Flow chart of sequence of operation

4.2.3 Writing the program

4.2.4

Input Output Description

Table 4.1: Input Output Description

Devices Start switch

Inputs 000.00

Devices Sol1(Clockwise rotation)

Outputs 010.00

Ls1(clockwise rotation) Ls2(Anti clockwise ) Ls3(Check graps work) PH1(Grasp) Stop switch Reset switch

000.06

Sol2(Anti clockwise)

010.01

000.07

Sol3(Grasp)

010.02

000.08

Conveyer A

010.03

000.09 000.01 000.02

4.3 Conclusion
This is a simulation control panel, with a programmable logic controller, PLC that allows programming and controlling a system as desired. What is PLC, how it works and programmed, and its hardware component every thing are here collected in this project theory.

Some introduction of PLC is described in this project report. Any body can get some idea about PLC infrastructure that is CPU, input module, output module etc.

Ladder diagram is a programming language of PLC, which is described here. The ladder diagram rung is made of normally open, normally close, timer, counter etc. How to create logic and program are also described here.

Omron PLC is used in this simulation panel, which is programmed with software named SYSWIN 3.4. Starting of software, writing program, download to PLC, upload the program from PLC, changing the mode of PLC etc are briefly described in the report.

The connection of PLC with computer, input / output panels and load connections etc all are. This simulation panel that is performed correctly tests an example and perfect result is found.

4.4 Discussion

This control system simulator is constructed with a PLC of 20 points of 4K Byte memory capacity which is executed within 1 second. So a system of 12 inputs and 8 outputs can be easily tested through this simulation panel. The conventional control systems with so many relay, timer, counter, magnetic contact etc. are reduced in tremendous amount. Therefore the cost of system reduced also system response as well as space also reduced for the control system used PLC. In this panel relay of 24V DC with contact of 250V used that would be replaced for higher ratings and then it would be used for controlling a system.

Reference:
[1] Crispin AJ. Programmable Logic Controller and their engineering applications: Books Britain, 1996. Johnson DJ. Programmable Controllers for factory automation: Marcel Dekker, 1987. Otter JD. Programmable Logic Controllers: Operation, Interfacing and Programming. Petruzella F. Programmable Logic Controllers, Second Edition: McGraw-Hill Publishing Co., 1998. Carrow, RA. Soft Logic: A guide to using a PC as a Programmable Logic Controller: McGrawHill Publishing Co., 1997. Training course on Programmable Logic Controllers: Training Institute for Chemical Industries, Polash, Narsingdi. Srivastava Kumar Pradeep ME, Exploring Programmable Logic Controllers with application: BPB Publication., 2003. www.omron.com www.seimensplc.com www.alenbradely.com www.trilogi.com

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[5]

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ANNAXTURE 01. Study the control system of Kapti Hydroelectric Power Station and adopting Programmable Logic Controller (PLC) in their system.

02. Study the control system of Chittagong Power Station and adopting Programmable Logic Controller (PLC) in their system. 03. Study the control system of T.K. Paper Mill and adopting Programmable Logic Controller (PLC) in their system. 04. Study the control system of Bangladesh Steel Re-rolling Mill and adopting Programmable Logic Controller (PLC) in their system.

05. Manual for Control System Simulator and adopting Programmable Logic Controller (PLC) in their system.