Finalpaper2014121425932854

International Journal of Innovative and Emerging Research in Engineering

Volume 1, Issue 2, 2014

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Available online at www.ijiere.com

International Journal of Innovative and Emerging

Research in Engineering e-ISSN: 2394 - 3343

An Analysis and Control of a PLC Based Module Taster

Maitrey Trivedia, Elizabeth Jyothi Shajan b, Anita Fulvanic

aBE Scholar, Department of EE, A.D.I.T. College, [email protected] bAssistant system Engineer, I B M I n d i a L i mi t e d , [email protected]

cAssistant Professor, Department of EC, L.J.I.T. College, [email protected]

ABSTRACT:

This paper aims to explain the operation and control of a module taster based on PLC. A discussion on the same in a

practical scenario has also been discussed with the help of hardware module and Simulation in Automation Studio

software. The aspects discussed are towards ease-of-use, design complexity and market acceptance.

Keywords: PLC, Module tester, Blow room, B&R Automation studio, Control diagram.

I. INTRODUCTION

PLC that is known as ‘Programmable Logic Controller’ is a basically essential need of industrial environment. Now days, the

application of PLC is widely known and used in this digital world. PLC’s application is obviously applied at the industrial

sector. Normally, the PLC’s that have been used at the industrial field is usually to control a mechanical movement either of

the machine or heavy machine in order to create an efficient production and accurate signal processing [1]. The system sequence

of operation is designed by ladder diagram. Sensor usually plays vital role as an input signal transmitter for the PLC in this

system [13]. In a textile industry, all the functionality of machines is based on PLC like testing, measuring, and other important

industrial functions [2]. Here, we have discussed a common controlling machine mechanism using PLC and automation system

in which there are several machines with independent control. So, one require separate hardware for each and correspondence

a lot of time. So, to rectify this problem, we have discussed common hardware facility that will be useful to control all the

machines in a single hardware mechanism [5]. By developing this type of controller, automation of sequence machineries can

easily be done which controls the spinning of cotton. PLC monitors fault that are occurring in machineries and control

machineries by taking corrective majors continuously according to the faulty conditions. This gives more reliable and user

friendly control of spinning machineries [9].

II. PREFERENCE TO THE MODULE TESTER SCHEME

Automation is the use of control system 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. Automation plays an increasingly important role in the world

economy and in daily experience [4].The dictionary defines automation as “The technique of making an apparatus, a process,

or a system operate automatically.”We engineers define automation as “The creation and application of technology to monitor

and control the production and delivery of products and services.”[6].

PLC controller logic is use for automation in basic five steps:

1. Developing conventional circuit diagram.

2. Converting that conventional circuit diagram into block diagram.

3. Simulation and Programming in standard Software.

4. Installation of proposed program and hard ware.

5. Finally the testing which gives the result of programming and hardware is working properly is done.



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III. INTRODUCTION TO BLOWROOM

In Textile Industries, the number of machines arranged in a line on series to perform all the function to form a uniform lap form

cotton bale is called ‘blow room line’. These lines are mainly of two types depending upon the manufacturer [11].

1. Conventional Blow room Lines

2. Modern Blow room Lines

There are mainly five operations of a blow room:

1. Opening

2. Cleaning

3. Mixing or Blending

All of three are explained with their corresponding functions as below:

1. Opening: a) To open the compressed bales of fibers. b) To make the cotton tuft as small as far as possible.

2. Cleaning: To remove dirt, dust, broken seeds, broken leaves, and other foreign materials from the fibers.

3. Mixing & Blending: To make good value of yarn and to decrease production cost mixing and blending is done.

Figure 1. Block diagram of blow room with different blocks which shows modularized components using PLC

Figure 2. Front View of Actual blow room in modern blow room line

Different Blocks of a Blow room are discussed as below:

1) Bale Opener: Bale Opener Machine is the first major machine in blow room line for ring spinning.

Objectives:

1. To open the tuft of cotton.

2. To mix & blend the fiber.

3. To remove a considerable amount of trash from fiber this is taken out by fan.

4. To act as a reserver box for the next machine.

2) Pre Cleaner: A pre-cleaner is a device which is installed in the intake system of an engine before the Fine cleaner. It removes

much of the contamination and dirt from the incoming feed material.

3) Fine Cleaner: Fine cleaner machine is an important machine in ring spinning for cleaning and opening impurities from

cotton. This machine is set normally after porcupine opener machine.

4) Mixer: Mixer part is used for mixing cotton and man-made fiber.

5) Cards: Card has been designed for high production rates with virtually continuous running performance of fiber.

Various Applications of Blow room are listed below:

Bale Open

er

Pre-Cleaner

Fine cleaner

&

mixer

Carding



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1. The larger the dirt particle, the better they can be removed.

2. Cleaning efficiency can be different for different cottons.

3. The staple length of cotton can be significantly shortened.

4. Fibers with better elastic properties and improved spin ability can be produced.

IV. PLC PP35

In the figure 3, the back view of the PLC PP35 is shown which is used in the proposed scheme of module taster. Along with

figure, all the parts and components are also mentioned and corresponding functions is listed. We can see different information

in the display screen with using various function keys [3].

Figure 3. Back view of B&R PLC (PLC PP35)

1. Power Supply 24V DC

2. RS-232 Communication Port (Not Used)

3. CAN Port for Expansion Module

4. I/O Switch [When pressed and I/O LED is orange then Output states displayed]

5. Connector X2 16 Digital O/P 24V DC

6. Connector X1 16 Digital I/P 24V DC

7. Node Switch SW1 – Must be at 0

8. Node Switch SW0 – Must be at 1

9. Indication LED :

I/O LED : Green - State of all 16 Digital Inputs are indicated

Orange – State of all 16 Digital Outputs are indicated

Status LED : Green – RUN Mode

Red – STOP Mode or Error

V. SIMULATION

A programmable logic controller (PLC) is an industrial computer control system that continuously monitors the state of input

devices and makes decisions based upon a custom program, to control the state of devices connected as outputs. The basic

function of PLC is to provide output commands to a machine or process based on some combination of a set of input condition

to that machine or process [12]. This is the programming screen of the automation studio software. This programming language

is automation basic. The hardware of the PLC does not differ significantly from that of a lot of computers. What makes the

PLC special is the software. The Executive software is the program that the PLC manufacturer provides internal to the PLC,

which executes the user’s program. The executive software determines what functions are available to the user’s program, how

the program is solved, how the I/O serviced, and what the PLC does during power up or down and fault conditions. Input and

output (I/O) modules are specified according to the input and output signals associated with the particular application [6]. These



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modules fall into the categories of discrete, analog, high speed counter or register types. Discrete I/O modules are generally

capable of handling 8 or 16 and in some cases 32, on-off type inputs or outputs per module [11].

Figure 4. Simulation (HMI)/Programming screen of B&R Automation studio Software from which we can verify

input and output of particular program.

VI. OVERVIEW OF HARDWARE

A programmable logic controller, also called a PLC is a computer-type device used to control equipment in an industrial

facility. In a traditional industrial control system, all control devices are wired directly to each other according to how the

system is supposed to operate. In a PLC system, however, the PLC replaces the wiring between the devices. Thus, instead

of being wired directly to each other, all equipment is wired to the PLC. Then, the control program inside the PLC provides

the “wiring” connection between the devices. The PLC, being a microprocessor based device, has a similar internal

structure to many embedded controllers and computers [10]. One of the primary benefits of the standard is that it allows

multiple languages to be used within the same programmable controller. This allows the program developer to select the

language best suited to each particular task [8]. Ladder logic is the main programming method used for PLC's. As

mentioned before, ladder logic has been developed to mimic relay logic. The decision to use the relay logic diagrams was

a strategic one. By selecting ladder logic as the main programming method, the amount of retraining needed for engineers

and trades people was greatly reduced. The first PLC was programmed with a technique that was based on relay logic

wiring schematics. This eliminated the need to teach the electricians, technicians and engineers how to program - so this

programming method has stuck and it is the most common technique for programming in today's PLC [4]. PLC can be



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easily programmed. In the case of relay systems a lot of requiring is required and to achieve such changes, a hard-wired

relay panel has to be modified. We have used Siemens SMPS is used to convert 230V AC TO 24V DC [13].

Figure 5. Module mounting plate (Actual hardware)

Figure 6. Control diagram which shows expansion of the connection of input –output pins of BER 5 PLC



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Figure 7. Actual Mimic of B&R PLC module for particular control output

VII. FUTURE RECOMANDATIONS

Actually, a lot of weakness from the proposed scheme can be taken as future works so that the improved system will be

better in terms of performance [2].

So that, there are several recommendations or suggestions that we can take to increase performance in this scheme [7].

The performance of PLC based module taster can be increased .It will be better if we add more sensors in this system [8].

Thus, the system will be more sensitive as there will be more sensing points Besides using PLC as controller, the other

controller can be used in this future work is like Microcontroller [13].

However, many factors must be considered like cost [1].

VIII. CONCLUSION

In a nutshell, the theory and concept of module taster discussed here is based on PLC. Understandings of the desired operation

using PLC, Automation Studio software and how to use the ladder diagram to translate the machine sequence of operation are

the most important parts, because it has direct effect on the system performance. Finally, the basic operation and control using

PLC PP35 explained in this paper, can be used as references to design other applications of module taster, and also can be used

as a teaching material for the industrial control subject.

IX. REFRENCES

[1] Norman S. Nice, "Control System Engineering", Third Edition. California State Polytechnic University

Pomona.John Wiley & Son, Inc, 2000

[2] Siemens, "Basic Of PLCs", STEP 2000 series, Siemens Technical Education Program.

[3] J. S. Lee and P. L. Hsu, “A new approach to evaluate ladder diagrams and Petri nets via the if-then transformation”,

in Proc. IEEE Conf.SMC, Tucson, AZ, 2001, pp. 2711–2716.

[4] IEC International Standard: Programmable Controllers, Part 3: Programming Languages, IEC 61131-3,

International Electro technical Commission, 2003.

[5] E. Estévez, M. Marcos, and D. Orive, “Automatic generation of PLC automation projects from component-based

models” Int. J. Adv.Manuf. Tech., vol. 35, no. 6, pp. 527–540, 2007.



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[6] V. Hajarnavis und K. Young, "An Assessment of PLC Software Structure Suitability for the Support of Flexible

Manufacturing Processes", IEEE Trans. Autom. Sci. Eng., Bd. 5, Nr. 4, S. 641–650, Okt. 2008.

[7] J. Kim, I. Kang, J.-Y. Choi, und I. Lee, "Timed and Resource-Oriented State charts for Embedded Software", IEEE

Trans. Ind. Inform., Bd. 6, Nr. 4, S. 568–578, Nov. 2010

[8] Chun-Hsian Huang und Pao-Ann Hsiung, "Model-Based Verification and Estimation Framework for Dynamically

Partially Reconfigurable Systems", IEEE Trans. Ind. Inform., Bd. 7, Nr. 2, S. 287–301, Mai 2011.

[9] K. Thramboulidis und G. Frey, "Towards a Model-Driven IEC 61131-Based Development Process in Industrial

Automation", J. Softw. Eng. Appl., Bd. 04, Nr. 04, S. 217–226, 2011.

[10] L. Ramos, J. V. Ferreira, and J. Barcelo, “Model-based systems engineering: An emerging approach for modern

systems”, IEEE Trans.Syst., Man, Cybern. C, Appl. Rev., vol. 42, no. 1, pp. 101–111, Jan.2012

[11] M. Kellett, “A project-based learning approach to programmable logic design and computer architecture”, IEEE

Trans. Educ., vol. 55,no. 3, pp. 378–383, Aug. 2012.

[12] Vogel-Heuser, S. Braun, M. Obermeier, F. Jobst, und K. Schweizer, "Usability evaluation on teaching and applying

model-driven object oriented approaches for PLC software", in American Control Conference (ACC), 2012,

Montréal, Canada, 2012, S. 4463 –446.

[13] John W. Web and Ronald A. Reis ‘programmable logic controller’s principles And applications’,Sept-2012.

AUTHOR PROFILE

1. MAITREY TRIVEDI- Graduated (B.Eng) in Electrical

Engineering from A.D. Patel Institute of Technology in July, 2014.

His research interests are Industrial Instrumentation, Control systems,

Electrical Machines and Machine Design. He is currently working as

a NE Sales & Marketing Executive in TRIO Elevators India LTD,

Baroda. He has published 5 research articles so far on various topics

in different international journals at student level.

2. ELIZABETH JYOTHI SHAJAN -Received the B.E. in

Electronics and Communication Engineering from M.B. Patel

women’s institue of Engineering in july,2013.Her areas of interests

are embedded system, Image Processing, Advance Controllers and

PLC. She currently works as an assistant system engineer in IBM

India Ltd, Bangalore.

3. ANITA FULVANI- She completed her bachelor degree in

Electronics and Communication Engineering from M.B. Patel

women’s institute of Engineering in July, 2013.Her areas of interests

are embedded system, Audio-Video systems, Image Processing,

Advance Computer Networking, and PLC. She currently works as an

Assistant Professor in Electronics and communication Department of

L.J. Institute of technology, Ahmadabad.

Finalpaper2014121425932854

Documents

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independent control

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br automation studio