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This report was submitted as a part of undergraduate course in the department of electrical and electronic engineering of CUET (Chittagong University of Engineering & Technology)
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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 2.6: 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 3.6: 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 3.4: Output terminal 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
Electrical optical isolation
S2
Filter
Electrical optical isolation
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.
.
Figure 2.6: Load panel with eight lamps
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
Table 3.2: Output terminal address
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
Figure 3.5: Connection PLC with sensor panel
3.2.2 Connection PLC with relay panel
Figure 3.6: Connection PLC with sensor panel
Table 3.4: Output terminal address
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.