plc simulation report

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 0002023 &

MD ASRAFUL GONI 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 Title of the project Certificate of approval Dedication Acknowledgement Abstract Contents List of Figures List of table I INTRODUCTION 1.1 Definition of control

1.2 What is a Control System?

1.3 Types of control

1.4 Components of conventional sequential system

1.4.1 Switch

1.4.1.1 Momentary contact switch

1.4.1.2 Maintained contact switch

1.4.2 Relay

1.4.2.1 Components of Relays

1.4.2.2 Mode of Operation

1.5 Sequential Control

1.6 Advantages of Automatic Control

1.7 General concept

1.7.1 Programming Language and Technique

1.7.2 Real-Time operation/ orientation

1.7.3 Environmental Consideration

1.7.4 Maintenance and Trouble Shooting

1.7.5 Features and Advantages of PLC

1.8 Architecture

1.8.1 Power Supply Unit

1.8.2 Central processing unit (CPU)

1.8.3 Input Modules

1.8.3.1 Types of input components

1.8.4 Output Modules

1.8.5 Types of output components

1.8.6 Programming Device

1.8.7 Mechanical design of PLC system

1.8.8 Signal processing in PLC

1.8.9 Input/output processing

II DESIGN APPROACH

2.1 Simulation panel components

2.2 Steel frame

2.3 Steel frame with board

2.4 Materials required

2.4.1 Required steel angle

2.4.2 Required amount of other equipments

2.5 Block diagram of the overall simulation pane

2.6 Components description

2.6.1 Programmable Logic Controller

2.6.2 RS-232C Adapter (Interfacing unit)

2.6.3 Sensor panel

2.6.4 Load panel

2.6.5 Rare panel

2.6.6 Floor panel

2.6.7 Relays

2.6.8 Relay base

III DEVELOPMENT APPROACH

3.1 Panel layout

3.1.1 Input ports

3.1.2 Output ports

3.1.3 Sensor panel

3.1.4 Load panel

3.2 Wiring PLC with panels

3.2.1 Connection PLC with sensor panel

3.2.2 Connection PLC with relay panel

3.2.3 Connection relay contact with load panel

3.2.4 Connection with PC

3.2.5 PLC connection with host link

3.2.6 RS-232 connector configuration

3.3 Developed Simulation panel

IV PERFORMANCE CHECK

4.1 Coasting

4.2 Result

4.2.1 ROBOT control system

4.2.2 Sequence of operation by drawing the flowchart

4.2.3 Writing the program

4.2.4 Input Output Description

4.3 Conclusion

4.4 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 2.7: 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 3.7: 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 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.

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)

Disturbance

Control Element

Deviation

Controll

Correcting unit Process Measuring system

Correction Variable

Measured Variable

Desired

Outline

Differential Element

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.

Figure 1.3: Symbolic representation of different type of sequential switches

NO relay contact

NC relay contact

Start switch Stop switch

NO relay

contact

NC relay

contact

M

Auto/Manual

switch

A

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 coil-

actuated 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

Program

Memory

Timer

Counter

Flag

Process

input image

tables

Process

input image

tables

RAM

Figure 1.5: Block Diagram of a PLC

Processor Memory sub

module

Serial port ALU

ROM

I/O bus

I/O

modules

Digital Modules Analog Modules

- Input modules - Input modules

- Output modules - Output modules

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


S2

Filter


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

Figure 2.3: Block diagram of simulation panel

Personal computer

Interfacing Unit

Input

Module

P -

Output

Module

- C

CPU

- L-

Sensor panel

Load panel

24V DC Power

Supply for PLC

24V DC Power Supply for

Lamps

Power Circuit

Breaker

Power mains

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.

.


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

00 000.00

01 000.01

02 000.02

03 000.03

04 000.04

05 000.05

06 000.06

07 000.07

08 000.08

09 000.09

10 000.10

11 000.11

3.1.2 Output ports

Figure 3.2: Output ports layout


Output terminal no.

Address

00 010.00

01 010.01

02 010.02

03 010.03

04 010.04

05 010.05

06 010.06

07 010.07

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

00 000.00

01 000.01

02 000.02

03 000.03

04 000.04

05 000.05

06 000.06

07 000.07

08 000.08

09 000.09

10 000.10

11 000.11

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


3.2.2 Connection PLC with relay panel



Output terminal no.

Address

00 010.00

01 010.01

02 010.02

03 010.03

04 010.04

05 010.05

06 010.06

07 010.07

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

Figure 4.2: Flow chart of sequence of operation

Start

Button

Arm rotates clockwise

Arm at LS1

Conveyor A on

Photo eye

sense

Conveyor A off

Is LS3 on

Arm rotates counterclockwise

Arm at LS2

Release Workpiece

Is Ls3 off

NO

NO

NO

NO

NO

NO

Yes

Yes

Yes

Yes

Yes

Yes

SOL 1

SOL 2

4.2.3 Writing the program

4.2.4 Input Output Description

Table 4.1: Input Output Description

Devices Inputs Devices Outputs

Start switch 000.00 Sol1(Clockwise

rotation)

010.00

Ls1(clockwise

rotation)

000.06 Sol2(Anti

clockwise)

010.01

Ls2(Anti clockwise

)

000.07 Sol3(Grasp) 010.02

Ls3(Check graps

work)

000.08 Conveyer A 010.03

PH1(Grasp) 000.09

Stop switch 000.01

Reset switch 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.

[2] Johnson DJ. Programmable Controllers for factory automation: Marcel Dekker, 1987. [3] Otter JD. Programmable Logic Controllers: Operation, Interfacing and Programming. [4] Petruzella F. Programmable Logic Controllers, Second Edition: McGraw-Hill Publishing Co.,

1998. [5] Carrow, RA. Soft Logic: A guide to using a PC as a Programmable Logic Controller: McGraw-

Hill Publishing Co., 1997. [6] Training course on Programmable Logic Controllers: Training Institute for Chemical Industries,

Polash, Narsingdi. [7] Srivastava Kumar Pradeep ME, Exploring Programmable Logic Controllers with application: BPB

Publication., 2003. [8] www.omron.com [9] www.seimensplc.com [10] www.alenbradely.com [11] www.trilogi.com

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.

plc simulation report

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