Industry Automation with Programmable Logic Controller

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PresentationOn

“Industry Automation with Programmable Logic Controller”

Md. Arifur RahmanID# 08105054

Program: BSEEE

IUBAT- International University of Business Agriculture and Technology23rd, December 2011

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Objective

Main objective of this presentation is to show my practical work, what ever I learnt in practical field.

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Sequence

1. About Industry Automation2. PLC- Programmable Logic Controller3. Advantage of PLC control system4. PLC used in Niagara Textile ltd5. Typical work done by PLC in Niagara Textile LTD6. PLC Architecture7. PLC system8. Input/output section9. Programming device10.Device connectivity11.Practical Example12.Recommendation13.Conclusion

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About Industry Automation

Industry Automation is the uses of industry control system to reduce the need for human work in the production of goods and service. 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.

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PLC- Programmable Logic Controller

A Programmable Logic Controller is a specialized computer used to control machines and process.

PLC Uses a memory to store instructions and specific functions that include ON/OFF control, timing, counting, sequencing, arithmetic and data handling.

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Contd.

Figure 1: TSX-Micro 3722 PLC Used in Niagara Textile ltd

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Advantage Of PLC control System

FlexibleFaster Response timeLess and simple wiringSolid-state – no Moving partModular Design - easy to repair and expandHandle much more complex systemEasy to troubleshootLess expensive

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PLC Used in Niagara Textile

Two type PLC I saw in Niagara textile:

1. TSX-Micro 3722-1012. Logimate P160

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Typical work done by PLC in Niagara Tex:

1. Controlling of finish Fabrics Diameter2. Speed control of induction motor3. Water level control for dyeing machine4. Different type of temperature control5. Automatic dyeing processing with control6. Control finishing machine7. Control shift counter8. Identification of safety work.9. Emergency Alarm system

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PLC Architecture

Figure: Typical PLC Architecture

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PLC System

Figure: PLC System Construction

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The Processor

Is the brain of the PLC

Consists of a microprocessor for implementing the logic, and controlling the communications among the modules

Designed so the desired circuit can be entered in relay ladder logic form

The processor accepts input data from various sensing devices, executes the stored user program, and sends appropriate output commands to control devices.

Input/Output Section

I/O Section Consists Of :

Input Modules

Output Modules

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Input Module

Forms the interface by which input devices are connected to the controller.

Input device is physically wired into the system.

Like temperature sensor, water level sensor, pressure sensor.

Figure: Input Module

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Output Module

Forms the interface by which output field device are connected to the controller.

PLC employ an optical isolator which uses light to electrically isolate the internal components from the output terminal.

Figure: output module detail.

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Power Supply

Supplies DC power to other modules that plug into the rack

In a large PLC systems, this power supply does not normally supply power to the field device

In small and micro PLC systems, the power supply is also used to power field devices.

Figure : Power Supply Unit

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Programming Device

Figure: PLC connected with Programming device

A personal computer(PC) is the most commonly used programming deviceThe software allows users to create, edit, modify, and troubleshoot the program.The personal computer communicates with the PLC processor via a serial or parallel data communication link.

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Software

For PLC Programming:

1. PL7 4.4 2. Win pro ladder

For HMI Design:

3. Vijeo-Designer 1.1

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Basic Device Connectivity

PLC Connected with Laptop using serial Port

And inverter connected to PLC

Motor connected to Inverter.

So, here make a program in computer, transfer the program to PLC and control motor from PLC

Computer is also used for monitoring device activity.

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Contd.

Figure: PC-PLC Connectivity

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Cable Used for connection PC-PLC

Figure: RS-232 Cable Figure: PS2-USB Cable

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Sensors Connection

Here we can see Water level sensor and Hydrostatic sensor connected to PLC and transmit different types of signal to PLC

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Wire connectivity with PLC

Figure: Wire connectivity with PLC

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Human Machine Interface

This device is used for:

Manually control PLCMonitor device activity in different level

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Practical Example

Mixer Process Control Problem

Mixer Motor to automatically stir the liquid in the vat when the temperature and pressure reach at preset value

Alternate manual pushbutton control to start/stop motor manually.

The temperature and pressure sensors switches close their respective contacts when condition fulfill.

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Process Control Relay Ladder Diagram

Motor starter coil is energized when both the sensors are closed or pushbutton is pressed.

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PLC Input Module Connection

The same input field devices are used

Those devices are wired to the input module according to the manufacturers labeling scheme

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PLC Output Module Connection

Same output field device is used and wired to the output module

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PLC Ladder Logic Program

The format used is similar to that of the hard=wired relay circuit

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Entering And Running the PLC Program

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PLC Operation Cycle

During each operating cycle, the controller examines the status of input devices, executes the user program, and changes output accordingly.

The completion of one cycle of this sequence is called scan. The scan time, the time required for one full cycle, provides a measure of the speed of response of the PLC

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Personal Computer Based Control System

Advantages:

Lower Initial CostLess hardware and software requiredStraight-forward data exchange with other systemSpeedy information processingEasy customization

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Recommendation

Need skilled person in this automation field

Need extra course in study level

Make some part of Automation system wirelessly

Well this is a big sector and we have to take it seriously

Need more opportunity for practical works

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Conclusion

In my total internship period I learn lots of things related to industry automation. I tried to focus those things into my presentation.

Mostly I focused about automation and programmable logic controller. This presentation I try to show how I learn and how to work in practical field.

Most time I saw connectivity and controlling. This connectivity and controlling is related to programmable logic controller. PLC is so much important device in this sector. Plc doing many types of automation works in industrial field.