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Project One

EE5377 Programmable Logic Controller in Industrial Automation

Water Pump

Prepared by:Ghanshyam D. Zambare (1001433900)

Vimal K. Vankar (1001439728)

Under the guidance of Dr. Wei Jen Lee &

Mr. Yuhao Zhou

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INDEX

1. Summary… 3

2. Flow meter and its specifications…3

3. Connections4

4. Ladder diagram…5

5. Procedure…6

6. Results…6

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Summary:

The main idea behind the project was to design a flow measurement system using plc IP3416.Depending upon the time for which the pulses are generated, the water pump pumps water to the water tank. We need to set the counter accordingly so that when the counter reaches zero the pump should pump up to 1 liter of water to the water tank.

Flow Meter and its specification: A flow meter is used to measure the volume of the water flowing

through the flow meter. The device has the following specifications:ß Operation range: 0.3 – 6 L/min (The output (pulse/sec) of the flow

meter is proportion to the flow rate)ß The range of working voltage: DC5V-24Vß Maximum operating current: 15 mA (DC 5V)ß Load capacity: ≤ 10 mA (DC 5V)ß Use temperature: ≤ 80 ℃ß Operating humidity range: 35%~90%RH (no frost)ß Allowing pressure: pressure 1.2Mpaß Temperature: -25~+80 °Cß Electric strength 1250V/minß Insulation resistance ≥ 100MΩß Hydrostatic pressure testing ≤ 2.0Mpa

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Connections:

Plc is given an 110V supply from the mains. It is connected to the laptop via USB to RS232 cable using EPS.The supply voltage to the Flow meter is given from external powersupply, which was set to 22V. Output of the flow meter is connected to pin X32 which is a high speed optically isolated input. The output pulses from the flow meter makes the counter count down each time the PLC receives it.Three momentary switches are connected at pins X22, X23, X21 which are start, reset, and stop switches respectively. These switches arepowered by connecting the other ends of the switches to AGND pin and shorting the “+” and 5Vout pins.A 10V D.C. source is applied to the motor whose one end is connectedto “– “pin of the PLC.

Fig 1: Flow Meter set up.

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Fig 2: Switching Circuit

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Ladder Diagram:

Fig 3: Ladder Diagram

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Procedure:

1. 1 liter of water pumped in a water tank till the PLC gets the pulses from the flow meter.

2. The counter is adjusted with a count in such a way that when the counter reaches zero the PLC will stop receiving the pulses. Thus, the pump will stop pumping water any further.

3. Here initially we have loaded the counter using a single pulse, which will load the counter only once. Then the counter is displayed on the LED screen provided on the PLC.

4. We have used a momentary switch and prepared a latch for it. So, when we press the start button the flow meter starts generating the pulses which are given to the PLC which eventually starts thepump and water is filled in the water tank.

5. When 1 liter of water is filled in the water tank the motor stops pumping automatically.

6. We have provided stop and reset switch in our program so that we can stop the program in case of any emergence. Whereas reset switch is used to reset the counter and restart the whole process.

Team Member’s Role: Both the Team Members were actively involved at each stage of the project.

Results:

1. When we loaded 4060 count (which is a calibrated count) we observed 1024ml (including volume of the container) of water being poured.

2. After deducting the volume of the container, the actual volume of the water pumped by the water pump is 1024 – 34= 990. Where 34is the volume of the container in ml.

3. So we obtained the results with percentage error [(1000 – 990)/1000] *100 = 1%.