Presentation on

Industrial Automation
using PLC

INTRODUCTION
The project mainly tells about the
slicing of bread that is kept on the
conveyor belt.
An IR SENSOR is placed which will
ultimately sense the bread on the
conveyor belt and energizes the
slicing machine in order to perform
the task.

Block Diagram :

What is Automation?
Automation is the use of control systems and
information technologies to reduce the need for
human work in the production of goods and
services.
In the scope of industrialization, automation is a
step beyond mechanization.
Whereas mechanization provided human
operators with machinery to assist them with
the muscular requirements of work, automation
greatly decreases the need for human sensory
and mental requirements as well.

Need Of Automation
It increases productivity and reduces cost.
Replacing human operators in tasks that involve hard
physical or monotonous work.
Replacing humans in tasks done in dangerous environments
(i.e. fire, space, volcanoes, nuclear facilities, underwater,
etc.)
Performing tasks that are beyond human capabilities of size,
weight, speed, endurance, etc.
Automation is often applied primarily to increase quality in
the manufacturing process, where automation can increase
quality substantially.
Automation reduces power consumption and reduces man
power requirement.
Automation improves production quality.
Automation provides safer working conditions.

Components

PLC
IR SENSOR
CONVEYOR BELT
MOTOR
SMPS

Programmable Logic Controller (PLC)

A programmable logic controller

(PLC) or programmable controller
is a digital computer used for
automation of electromechanical
processes. . Programs to control
machine operation are typically
stored in battery-backed or nonvolatile memory.

PLC ADVANTAGE
Smaller physical size than hardwire solutions
Easier and faster to make changes.
PLCs have integrated diagnostics and
override functions.
Diagnostics are centrally available.
Applications can be immediately
documented.
Applications can be duplicated faster
and less expensively.

COMPONENTS OF PLC

PLC OPERATION

There are four basic steps in the

operation of all PLCs
1. Input Scan
2. Program Scan
3. Output Scan
4. Housekeeping

BLOCK DIAGRAM OF CONTROL

SYSTEM

SCADA
SCADA stands for Supervisory
Control and Data Acquisition. It refers
to an industrial control system: a
computer system monitoring and
controlling a process

SCADA SYSTEM

Switched Mode Power Supply:

An electrical power supply that incorporates a
switching regulator to convert electrical power
efficiently.
It transfers power from a source, to a load, while
converting voltage and current characteristics.

Advantages of SMPS over Linear Power

Supplies:

1.
2.
3.
4.
5.
6.

Lower weight
Smaller size
Higher efficiency
Lower power dissipation
Wide ac input voltage range
Reduced costs

Disadvantages of SMPS:
1. Complexity of the circuit

Block diagram of a SMPS

1. Input rectifier stage:

It is used to convert an ac input to dc. A
SMPS with dc input does not require this
stage. The rectifier produces unregulated dc
which is then passed through the filter circuit.

2. Inverter stage:
The inverter stage converts DC, whether directly from the
input or from the rectifier stage described above, to AC by
running it through a power oscillator, whose output
transformer is very small with few windings at a frequency of
tens or hundreds ofkilohertz.
3. Output transformer:
- If the output required is to be isolated from input, the
inverted AC is used to draw the primary windings of a high
frequency transformer. This converts the voltage up or down to
the required output level on its secondary winding.
4. Output rectifier:
- If the dc output is required, the ac output from the transformer
is rectified.
5. Regulation:
- Feedback circuit monitors the output voltage and compares it
with the reference voltage.
. In our project we are using the SMPS to convert ac to 24 v
dc,which is then used as the power supply for plc.

IR SENSOR
Infrared sensor is used to sense the object.
An emitter is simply an IR led .
The detector is simply an IR photodiode ,
sensetive to the light of same wavelength used
by the IR LED.
When IR light falls on the photodiode, The
resistances and the output voltages, change in
proportion to the magnitude of the light received
by the IR sensor
The output of the sensor will acts as input of the
plc for controlling .

Sharp GP2Y0A41SK0F Distance Sensors

Features
Operating voltage: 4.5V to 5.5V
Average current consumption: 12mA
Distance measuring range: 4cm to
30cm
Update period: 16.54ms
The GP2Y0A41 uses a 3-pin JST PH
connector that works with our 3-pin
JST PH cables for Sharp distance
sensors

D.C. MOTOR
1. INSIGHT THE D.C. MOTOR.
2. OUTER BODY OF GEAR HEAD AND
OVERVIEW.
3. INTERNAL STRUCTURE.
4. BOTTOM GEAR ASSEMBLY.
5. COMBINATION OF GEAR ASSEMBLIES.
6. WORKING.

INSIGHT THE D.C. MOTOR

Geared DC motors can be defined as an extension
of DC motor which already had its Insight details
demystifiedhere. A geared DC Motor has a gear
assembly attached to the motor. The speed of
motor is counted in terms of rotations of the shaft
per minute and is termed as RPM .The gear
assembly helps in increasing the torque and
reducing the speed. Using the correct
combination of gears in a gear motor, its speed
can be reduced to any desirable figure. This
concept where gears reduce the speed of the
vehicle but increase its torque is known as gear
reduction. This Insight will explore all the minor
and major details that make the gear head and

EXTERNAL STRUCTURE

OUTER BODY OF GEAR

HEAD

REAR VIEW OF D.C.MOTOR

INTERNAL STRUCTURE
On opening the outer plastic casing of the
gear head, gear assemblies on the top as well
as on bottom part of the gear head are visible.
These gear assemblies are highly lubricated
with grease so as to avoid any sort of wear
and tear due to frictional forces. Shown below
is the top part of the gear head. It is
connected to rotating shaft and has one gear
that allows the rotation. A strong circular
imprint shows the presence of the gear that
rotates the gear at the upper portion.

GEAR STRUCTURE

BOTTOM GEAR ASSEMBLY

STRUCTURE EXPLANATION
The gear assembly is set up on two
metallic cylinders whose working can
be called as similar to that of an axle.
A total of three gears combine on
these two cylinders to form the
bottom gear assembly out of which
two gears share the same axle while
one gear comes in between them
and takes a separate axle.

The gears are basically in form of a

small sprocket but since they are not
connected by a chain, they can be
termed as duplex gears in terms of a
second cog arrangement coaxially
over the base. Among the three
gears, two are exactly same while
the third one is bigger in terms of
the number of teeth at the upper
layer of the duplex gear. The third
gear is connected to the gear at the
upper portion of the gear head. The

COMBINATION OF GEAR
ASSEMBLIES

WORKING
The DC motor works over a fair range of
voltage. The higher the input voltage more is
the RPM (rotations per minute) of the motor. For
example, if the motor works in the range of 612V, it will have the least RPM at 6V and
maximum at 12 V.
In terms of voltage, we can put the equation as:
RPM= K1 * V, where,
K1= induced voltage constant
V=voltage applied

The working of the gears is very

interesting to know. It can be explained
by the principle of conservation of
angular momentum. The gear having
smaller radius will cover more RPM than
the one with larger radius. However, the
larger gear will give more torque to the
smaller gear than vice versa. The
comparison of angular velocity between
input gear (the one that transfers
energy) to output gear gives the gear
ratio. When multiple gears are connected
together, conservation of energy is also

In any DC motor, RPM and torque are

inversely proportional. Hence the
gear having more torque will provide
a lesser RPM and converse. In a
geared DC motor, the concept of
pulse width modulation is applied.
The equations detailing the working
and torque transfer of gears are
shown below:

PLC CONTROLLED
D.C.MOTOR

CONVEYOR BELTS
A belt
conveyor is
rubber or
textile
structure with
a belt shape
closed ring
with a
vulcanised or
metalic joint
used for
material
transportatio

component

TYPES OF BELTS

TILE BELT OR SMOOTH TEXTILE (UNE 18

Quality of the
cover

Quality of the frabic