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IMPLEMENTATION OF AUTOMATION CONTROLLER USING ELECTRO- PNEUMATIC & PLC FOR FOOD PROCESSING NASITA BINTI IBRAHIM This thesis is submitted as partial fulfillment of the requirements for the award of the Bachelor Degree of Electrical Engineering (Electronics) Faculty of Electrical & Electronics Engineering Kolej Universiti Kejuruteraan & Teknologi Malaysia APRIL, 2006 PERPUSTAKMN KOIEJ UNIVERSITI KEJURUTERAAN & TEKNO100 MALAYS No. Peràèhan - No. Par.gg4sn 018599 T*lkh 11 JUL 2006
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Page 1: IMPLEMENTATION OF AUTOMATION CONTROLLER USING ...

IMPLEMENTATION OF AUTOMATION CONTROLLER USING ELECTRO-

PNEUMATIC & PLC FOR FOOD PROCESSING

NASITA BINTI IBRAHIM

This thesis is submitted as partial fulfillment of the requirements for the award of the

Bachelor Degree of Electrical Engineering (Electronics)

Faculty of Electrical & Electronics Engineering

Kolej Universiti Kejuruteraan & Teknologi Malaysia

APRIL, 2006

PERPUSTAKMN KOIEJ UNIVERSITI

KEJURUTERAAN & TEKNO100 MALAYS No. Peràèhan - No. Par.gg4sn

018599 T*lkh

11 JUL 2006

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ABSTRACT

This project describes a design and Implementation of Automation Controller

using Electro pneumatic and PLC for food processing. The proposed model system

is designed based of the usage of pneumatic, electro pneumatic and Programmable

Logic Controller (PLC). This project is focus to small medium industry (SMI). SMI

is defined as manufacturing companies or companies providing manufacturing

related services with annual sales turnover not exceeding RM25inillion and with full-

time employees not exceeding 150. The aim of this project is automating the

processing food in the industry that still using manual system. It because many

industry nowadays using automation machine in processing their production.

Automation machine can gives more advantages to the industry such as it can

improve quality and accuracy of the product, increase productivity and also

tremendous amounts of power and energy which humans do not possess will be

decrease by using automatic machines like electro-pneumatic and PLC. The electro

pneumatic and PLC design will be proposed to that process in prototype model. This

system can be applied in industry factories that are developed to automatic system.

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ABSTRAK

Projek im adalah bertujuan untuk mereka sebuah aplikasi untuk

mengautomatikkan mesin memproses makanan.Projek im menggunakan asas

pneumatik,elektropneumatik dan .PLC sebagai perantará.Projek mi adalah lebih

tertumpu kepada industri makanan kecil dan sederhana (SMI),Industri sederhana

ringan im didefinasikan sebagai syankat pembekal atau syarikat yang menyediakan

perkhidmatan yang mendapat pulangan tahunan atau syankat yang menyediakan

perkhidmatan pekeija sepenuh masa yang tidak melebihi RM25 juta dan

menyediakan pekerja sepenuh masa yang tidak melebihi 150 orang.Matlamat bagi

projek mi adalah untuk mengautomatikkan mesin pemprosesan makanan yang masih

dijalankan secara manual di sesetengah industri pemprosesan makanan.Ini kerana

kebanyakan industri sekarang im menggunakan mesln automatik dalam perusahaan

mereka,.Mesin automatik memberi banyak kelebihan kepada industri kerana ia boleh

membaiki kualiti dan ketepatan sesuatu produk, meningkatan produktiviti dan

mengurangkan tenaga manusia dengan menggunakan elektro-pneumatik dan

PLC.Sistem rekaan menggunakan elektropneumatik dan PLC yang dihasilkan mi

adalah dalam bentuk prototaip.Sistem im akan diaplikasikan di mana-mana kilang

industri yang ingin mengautomatikkan system mereka.

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TABLE OF CONTENTS

CHAPTER TITLE PAGE

DECLARATION II DEDICATION ljj ACKNOWLEDGEMENTS iv ABSTRACT v ABSTRAK vi TABLE OF CONTENTS vii LIST OF TABLES ix LIST OF FIGURES x LIST OF APPENDICES xi

INTRODUCTION 1 1.1 Introduction 1

1.1.1 Automation and the advantages 1 1.1.2 Pneumatic and Electro-pneumatic 4 1.1.3 Programmable Logic Controller (PLC) 4

1.2 Overview 5 1.2.1 Problem statement 6 1.2.2 Objective 7 1.2.3 Scope 7

1.3 Thesis outline 7

2 LITERATURE REVIEW & METHODOLOGY 9 2.1 Introduction 9 2.2 Literature review 9

2.2.1 Fundamentals of pneumatic control technology 9 2.2.2 The fundamental of electro-pneumatic 9 2.2.3 Survey on SMI 9

2.3 Methodology 13

3 IIARWARE AND SOFTWARE 16 3.1 Introduction 16 3.2 Electro-pneumatic 17 3.3 Programmable Logic Controller 23

vii

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4 RESULT 26 4.1 Introduction 26 4.2 Packaging process 26

Using electro-pneumatic with relay signal 4.2.1 processing 27

Using electro-pneumatic with PLC signal 4.2.2 processing 34

4.3 Filling process 36 Using electro-pneumatic with relay signal

4.3.1 processing 36 Using electro-pneumatic with PLC signal

4.3.1 processing 40 4.4 Comparison between relay control system and PLC 43

5 CONCLUSION AND RECOMMENDATION 44 5.1 Introduction 44

5.1.1 Conclusion 44 5.1.2 Recommendation 45

REFERENCES 46 Appendices 47-63

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LIST OF TABLES

TABLE NO. TITLE PAGE

2.2 The process of"keropok kering" 11-13

3.4 List of components 20-22

4.2 List of components for packaging process 27

4.10 Table of symbol definition for packaging process 34

4.14 List of components for filling process 38

4.17 Symbol definition for filling process 41

EM

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LIST OF FIGURES

FIGURES NO. TITLE PAGE

1.1 Level of automation 2

1.2 Pattern automation by company size 3

2.1 The process of "keropok kering" 10

2.3 Flow chart of methodology 14

3.1 Relay as signal processing 16

3.2 PLC as signal processing 17

3.3 Procedure for develop pneumatic control system. 18

3.5 Components of PLC 27

3.6 Development of PLC program 28

4.1 Packaging process 27

4.3 Pneumatic circuit diagram of the packaging device 28

4.4 Procedure of designing the relay circuit diagram. 29

4.5 Sensor evaluation 30

4.6 First sequence step 31

4.7 Second sequence step 32

4.8 Third sequence step 33

4.9 Fourth sequence step 34

4.11 Circuit diagram, electrical 35

4.12 Ladder diagram of packaging process 35-36

4.13 Filling process 37

4.15 Pneumatic circuit diagram of filling process 39

4.16 Relay circuit diagram 40

4.18 Circuit diagram, electrical 41

4.19 Ladder diagram of filling process 42

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LIST OF APPENDICES

APPENDIX TITLE PAGE

A Basic LAD instructions 48-63

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CHAPTER 1

INTRODUCTION

1.1 INTRODUCTION

The transformation of the manufacturing industry into automation sector with

high value-added, capital intensive, high technology as well skill and knowledge

structure will increase the efficiency and productivity of Malaysian industries

especially to small medium industry (SMI). Small and medium industry in the

manufacturing, manufacturing related services and agro-based industries are industry

with full-time employees not exceeding 150 or with annual sales turnover not

exceeding RM25 million.

1.1.1 Automation and the advantages

Why automate? Let looks at the story from Fortune magazine entitled,

"Manufacturing the Right Way." A small part of this article, quoted here, refers to

the Caterpillar factory in East Peoria, Ilinois, and its factory redesign. The story

describes the presence of old technology side-by-side with new, automated

technology.

[The Caterpillar plant]. .tums Out 120 types of transmission for the whole

catalogue of Caterpillar machines In the area where transmission cases are prepared

for assembly, a along line of 35 machine tools, each requiring its own operator,streches down one side of the aisle. On the other side are four (of an

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eventual 32) flexible cellular systems. Both the same work of milling, drilling,

boring, tapping, debarring and reainblmg the crude steel from the foundry.

Because the old machines can handle only one kind of case at a time, the area

around them is jammed with bins of cases waiting to go through in batches. When a

batch is finished, the operator spends anywhere from four hours to two days setting

up the next batch. Once he is ready, he might need two or three tries to get the tool

running right. With adjustments being made at 35 stations, many $1000 cases end up

in the scrap heap before the next batch runs through smoothly.

Automation will help a manufacturing facility to:

1. Gain complete control of the manufacturing process.

2. Achieve consistency in manufacturing.

3. improve quality and accuracy

4. work in difficult or hazardous environments

5. increase productivity.

The pie chart in figure 1.1 [1] below shows to us about the increasing of automation

between year 1996 and 2000.

High N,e

MI

10%

High 10%

di D Meum

1996 2000

Figure 1.1: Level of automation

High level automation means more than 70% to full automation

Medium level automation means indicates to 40-70% automation

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Low level of automation means less than 40% automation

The proportion of companies with high level of automation more than

doubled from 3.5% in 1996 to 9.6% in 2000.Compames with medium level

automation rose to 34.5% in 2000 in from 18.2% in 1996.Consequently, the

proportion of companies that indicated low level automation was reduced by 19% to

49%.About 7% is still without automation as compared to 10% in 1996.Overall, the

extend of automation has increased.

The graph in figure 1.2 111 below tells us about the pattern of automation by

company size.

Figure 1.2: Pattern automation by company size

The pattern of automation by company size shows that larger companies are

inclined to have greater extent of automation. On other hand, small and medium size

companies recorded lower level of automation. A total 56.2% of large companies (

more than 500 employees) have medium to high level automation as compared to

36.9% in small companies(less than 100 employee).About 17% of small companies

have not implemented any automation( 1996:28%).

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1.1.2 Pneumatic and Electro-pneumatic

Electro pneumatics is used in many areas of industrial automation.

Production, assembly and packaging Systems worldwide are driven by electro

pneumatic controls. Electro pneumatic controls can combine the best features of

electronic and pneumatic controls; such system can consist of pneumatically actuated

valves, electrical/electronic controllers, sensors and control systems, plus electro

pneumatic positioflers or converters.

In contrast to a purely pneumatic control system, electro pneumatic

controllers are not shown in any single overall circuit diagram, but in two separate

circuit diagrams-one for the electrical part and one for the pneumatic part. For the

reason, signal flow is not immediately clear from the arrangement of the components

in the overall circuit diagram.

Electro pneumatic controllers have the following advantages over pneumatic control systems:

• Higher reliability ( fewer moving parts subject to wear)

• Lower planning and commissioning effort, particularly for complex controls.

• Lower installation effort, particularly when modem components such as valve

terminals are used.

Simpler exchange of information between several controllers

1.1.3 Programmable Logic Controller ( PLC)

The question, "Why use a PLC?"Really should rephrase to, "Why automate?"

Programmable logic controller (PLC5) is used in every aspect of industry to expand

and enhance production. Where older automated systems would use hundreds or

thousands of relays, a single PLC can be programmed as a replacement. PLCs have

been gaining popularity on the factory floor and will probably remain predominant

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for some time to come. Most of this is because of the advantages they offer

includes:-

Cost effective for controlling complex systems.

Flexible and can be reapplied to control other systems quickly and easily.

Computational abilities allow more sophisticated control.

Trouble shooting aids make programming easier and reduce downtime.

Reliable components make these likely to operate for years before failure.

The S7-300 is the universal PLC for a wide range of applications in

automation engineering - with the emphasis on production engineering. Its modular

construction without fans, simple implementation of distributed structures and user

friendly orientation make the S7-300 an economical and practical solution for a wide

range of automation functions. The outstanding features of the S7-300 include:

high processing speeds for short cycle times

powerful instruction set for complex functions

compact design for use in confined spaces

• 100% maintenance free

1.2 Overview of the implementation of automation controller using electro pneumatic and PLC

Nowadays, many industries using automation machine in processing their

production. It because using automatic machines to control processes is we can

harness tremendous amounts of power and energy which humans do not possess.

Electro pneumatic is successfully used in many areas of industrial automation.

Production assembly and packaging systems worldwide are driven by electro pneumatic control systems.

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LC

This implementation of automation controller is divided into three parts, first,

implementation by using pneumatic and electro pneumatic control system, in which

relays are used for signal processing. Second, by using programmable logic

controller-PLC (SIEMENS) as signal processing for electro pneumatic control

system and third, make a comparison between part one and two.

For the part l,in a pneumatic control, pneumatic components are used, that is,

variable types of valves,sequencers,air barriers, etc.In an electro pneumatic control,

the signal control section is made up of an electrical components, for example with

electrical input buttons, proximity switches or relays. Signal processing is

implemented by means of suitable wiring of relay coils and contacts.

For the part 2, the programmable microprocessor system of the PLC

undertakes all signal processing part of an electro pneumatic controller. Lastly, the

part is describing about the comparison between part 1 and part 2.

1.2.1 Problem Statement

Fish crispy is a snack made from fish, which is popular among Malaysians

people. This product is produced by small food industry which still using manual

system to process it. From this project, it will give more benefits to this industry

because it upgrades the manual system in their production to the automatic system.

From the automation we can improve the productivity of processing product. It

because manual system gives more disadvantages such as dispensing ingredients is

not similar for each process, the processing of manual system is slow because human

take a longer time to finish one process to another process and also industry need

more employees to process the product.

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1.2.2 Objective

The main objective in this project is to implement automation controller in

order to upgrade the technology for processing food industry that still using fully

manual processing system. This is can achieve by using:

Pneumatic and electro pneumatic

Electro pneumatic controlled by PLC(SIEMENS)

After implement these entire controller to the design, I will make comparison which the controller is suitable and has more advantages to implement it to the selected food processing.

1.2.3 Scope

This project is focus on the basic and electro pneumatic and PLC(Siemens)

• All the components used is from pneumatic workstation in lab.

This project is not real application and it's just a model in education type

13 Thesis outline

Chapter 1 explains about the background of automation controller that has been

used in this project. It briefs about the usage of electro pneumatic and programmable

logic controller (PLC) also their advantages. This chapter also includes the overview

of this project including the problem statement, objectives and scope. Chapter 2 explains about the literature review which includes the sources that has

been referred for the entire of this project. The sources that have been used are books and internets.

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Chapter 3 focuses the methodologies of implementation of automation controller

using e1ectrO-pneumatic and PLC for food processing. It gives the brief review of all

the methods includes: by using electro-pneumatic with relay or PLC as signal

proceSSmg.

Chapter 4 discusses all the results of this project obtained and the limitation of this

project.

Chapter 5 discusses the conclusion of development this project and it also includes

the problem and recommendations for the future modification.

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CHAPTER 2

LITERATURE REVIEW & RESEARCH METHODOLOGY

2.1 INTRODUCTION

This chapter describes about the literature review and research methodology of

this project.

2.2 LITERATURE REVIEW

2.2.1 Fundamentals of pneumatic control technology. [21

There are certain automation systems that allow for human substitution when

performing a certain task in a manufacturing system. System that can perform small

tasks, calculation and make decisions are referred to as automation systems.

Automation systems depend on the type of technology being used. Pneumatic is one

of automation systems that made by using components which uses compressed air.

2.2.2 The fundamental of electro-pneumatic[3]

Electro-pneumatic is one of the automation systems that used in many areas of

industrial automation. Production, assembly and packaging systems worldwide are

driven by electro pneumatic controls.

FA

2.2.3 Survey on Small Medium Industry (SME) factory

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i) Address of SME factory

KeropOk Kering

Na Nazml

2N Pusat Video Geliga, Kg. Geliga,

Kuala Kemamafl , 24000 Kemaman

TerenggaflU Darul Iman

The process of "keropok kering"

The figure 2.1 and table 2.2 below shows the process of "keropok kering".

Mix the minced fish meat with sago flour, salt, sugar and monosodium gisto

itir the mixture until it becomes soft dough

[Mixture is molded in cylinder shape

Steam or boiled

Cooled j

Cut into thin slices

Dry under the sun thoroughly, then deep-fry in hot Oil

[Packaging

Figure 2.1: The process of"keropok kering"

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I

Process Picture

a) Mixture ingredients process

_____• t * -

- I

b) Stir the mixture process

' C) Mixture is molded into

cylinder

shape AW

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IL

- I A

1I,

-(

yrw. I------.

I ' .. - -

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Ij

Table 2.2: The process of"keropok kering"

2.3 METHODOLOGY

Figure 2.3 below shows the process of method that has been used in this project.

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Figure 2.3: How chart of methodology

a) Data Collection

To succeed this project, the data has been taken from the visiting SMI (Small

Medium Industry) The SMI that has been selected is "keropok keping" factory. This factory is still using manual system in producing their product. So, the aim of this

project is to automate their system using the basic pneumatic, electro pneumatic and

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PLC.After visiting this factory, two processing has been chosen for this project

which is the packaging keropok keping and the bottling sauce process.

b) Design control system

In designing the control system of this project, three control system has been

used which are by using basic pneumatic, electro pneumatic and programmable logic

controller.

C) Testing and modification

After designing the control system, the design will test at the workstation in

the lab. If the design not success, the modification will be taken.

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CHAPTER 3

HARDWARE AND SOFTWARE

3.1 INTRODUCTION

This chapter focused on the hardware and software for the implementation of

automation controller using electro pneumatic and programmable logic controller-

PLC (SIEMENS).For the part 1, the project is focused on implementation automation

controller by using pneumatic and electro pneumatic control system, in which relays

are used for signal processing. Figure 3.1 shows the relay as a signal processing.

Signal Signal processing Signal' input i output

Switch Relays Contacts

OilS2 K2

rr

S3 K3 K3 K4 H 2

rr

Relay- controlled

Figure 3.1: relay as signal processing

IV