Chapter No 1: Automation

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Chapter No 1
Automation

Chapter No-1:Automation

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Automation:
Automation can be defined as a technology concerned with performing a process by means of
programmed commands combined with automatic feedback control to ensure proper execution
of the instructions. The resulting system is capable of operating without human intervention.
The use of control systems such as computers, pre-programmed overhead cranes, automated
assembly lines, automated painting shops etc etc so that the load on human operators is reduced
leading to a better quality product with fewer overheads and minimal throughput time.
E.g. in the shop floor, welding is done by hand--now they have mechanical arms doing it. Same
with steel cutting, it is now done by lasers.

1.1 BASIC COMPONENTS OF AUTOMATION:

Figure 1.1 components of automation

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1.2 TYPES OF AUTOMATION:
Although automation can play a major role in increasing productivity and reducing costs in
service industriesas in the example of a retail store that installs bar code scanners in its
checkout lanesautomation is most prevalent in manufacturing industries. In recent years, the
manufacturing field has witnessed the development of major automation alternatives. Some of
these types of automation include:
Information technology (IT)
Computer-aided manufacturing (CAM)
Numerically controlled (NC) equipment
Robots
Flexible manufacturing systems (FMS)
Computer integrated manufacturing (CIM)
Information technology (IT) encompasses a broad spectrum of computer technologies used to
create, store, retrieve, and disseminate information.
Computer-aided manufacturing (CAM) refers to the use of computers in the different
functions of production planning and control. CAM includes the use of numerically controlled
machines, robots, and other automated systems for the manufacture of products. Computer-aided
manufacturing also includes computer-aided process planning (CAPP)group technology (GT),
production scheduling, and manufacturing flow analysis.
Numerically controlled (NC) machines are programmed versions of machine tools that execute
operations in sequence on parts or products. Individual machines may have their own computers

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for that purpose; such tools are commonly referred to as computerized numerical controlled
(CNC) machines.
Robots are a type of automated equipment that may execute different tasks that are normally
handled by a human operator. In manufacturing, robots are used to handle a wide range of tasks,
including assembly, welding, painting, loading and unloading of heavy or hazardous materials,
inspection and testing, and finishing operations.
Flexible manufacturing systems (FMS) are comprehensive systems that may include
numerically controlled machine tools, robots, and automated material handling systems in the
manufacture of similar products or components using different routings among the machines.
Computer-integrated manufacturing (CIM) system is one in which many manufacturing
functions are linked through an integrated computer network. These manufacturing or
manufacturing-related functions include production planning and control, shop floor control,
quality control, computer-aided manufacturing, computer-aided design, purchasing, marketing,
and other functions. The objective of a computer-integrated manufacturing system is to allow
changes in product design, to reduce costs, and to optimize production requirements.
1.3 PROBLEM STATEMENT (BATCH PROCESS):
Batch production is the manufacturing technique of creating a group of components at a
workstation before moving the group to the next step in production. Batch production is common
in bakeries and in the manufacture of sports shoes, pharmaceutical ingredients (APIs), food
manufacturing, inks, paints and adhesives

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1.2.1 Automation of Batch Process:
The batch control system is used in a batching system for controlling the batching of a fluid
material from one container to another container. Control means for use in a batching system for
controlling the batching of a fluid material from one container to another container. We took this
project as automation of batch controlling system is one of the main advanced manufacturing
industries requirement .our project is totally based and focused on automated controlling of
different features included in batch process from industrial point of view such as controlling of
flow, speed, pressure, timing and also switching of electrical instruments. The automation of
batch control is very demanding and important in advanced manufacturing industrial system.
So focusing on the industrial demand and requirement we took the decision to work on
automation of batch control system using PLC.
1.2.2 Advantages:
Simple, convenient and standard-compliant automation
More flexible production
Shorter "Time to market" by minimizing engineering and validation effort
Optimized plant efficiency
Simple quality management
Lower validation costs due to traceable changes of recipes

1.2.3 why we use PLC instead of other controlling systems.
The main difference from other computers is that PLCs are armored for severe conditions (such
as dust, moisture, heat, cold) of industrial environment.The second distinction of plc is that their
hardware and softwares are designed for easy use by plant electricians and technicians. The

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hardware interfaces for connecting devices is actually the part of plc itself and are easily
connected.
When deciding whether to use a PLC based system or hardware relay system designer must think
of several questions i.e. need of high reliability, increased capability and out put required,
possible frequent control logic changes, need for
rapid modification, similar control logic valid for different machines, and specially the cost. The
merits of PLC system make them suitable than relay for such applications where the above
demands are required.
1.4 INSTRUMENTS OVERVIEW IN AUTOMATION OF BATCH PROCESS:
Programmable logic controller(PLC)
Programmable controllers or PLCs are solid state members of computer family used
integrated circuits instead of electromechanical devices to implement control functions.
A PLC can store instructions like timing, sequencing, counting, arithmetic data
manipulation and communication to control industrial machines. A PLC operates at different
computer rates commonly called the baud rate.
3-phase induction motor:
3-phase induction motor is the most widely used motor in the world for different
purposes. We found its used in both home as well as in industrial application. In our
project we are using induction motor for stirrer moving so the speed of the motor and
timing for the automatic on-off of the motor is controlled via plc.

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When power is applied to an induction motor it runs at its rated rate speed. While in
many applications variable speed is required. for example, in different pharmaceutical
companies, different liquids and substrates in a recipe are shacked at different speeds.
This speed of the stirrer is directly proportional to the speed of stirrer.
Frequency Inverter:
It is a device, or machine that changes an alternating current from one frequency to
another, with or without a change in voltage or number of phases. Also known as
frequency changer; frequency translator. In our project we are controlling the RPM of
frequency via plc and made frequency signal set constant.
press control:
It is capable for detecting both pressure and flow simultaneously as well as automatically
managing the pump operation. it is totally reliable ,resistant and easy to install.
Solenoid valve:
A solenoid valve is an electromechanical valve for use with liquid or gas. The valve is
controlled by an electric current through a solenoid coil. Solenoid valves may have two
or more ports: in the case of a two-port valve the flow is switched on or off; in the case
of a three-port valve, the outflow is switched between the two outlet ports. Multiple
solenoid valves can be placed together on a manifold.Solenoid valves are the most
frequently used control elements in fluidics. Their tasks are to shut off, release, dose,
distribute or mix fluids. They are found in many application areas. Solenoids offer fast

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and safe switching, high reliability, long service life, good medium compatibility of the
materials used, low control power and compact design.
Thermocouple:
A thermocouple is made of a pair of wires of different metals, such as iron and copper,
whose ends are welded together. The welded point is called the "junction". When the
junctions are at different temperatures, as shown in Figure 1, the thermal electromotive force
(emf, millivolt) is generated between them.
Temperature Transmitter:
When there is change in temperature the resistance of the thermocouple is changed and there
is very minute change in voltage, which is round about 0 to 20mA. This small voltage is very
minute to be sensed by PLC

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Chapter No 2
Batch process

Chapter No-2:Batch Process

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2.1 BATCH PROCESS:
Batch production is the manufacturing technique of creating a group of components at a workstation
before moving the group to the next step in production. Batch production is common in bakeries and in
the manufacture of sports shoes, pharmaceutical ingredients (APIs), food manufacturing, inks, paints
and adhesives. In the manufacture of inks and paints, a technique called a color-run is used. A color-run
is where one manufactures the lightest color first, such as light yellow followed by the next increasingly
darker color such as orange, then red and so on until reaching black and then starts over again. This
minimizes the cleanup and reconfiguring of the machinery between each batch. White (by which is
meant opaque paint, not transparent ink) is the only color that cannot be used in a color-run because a
small amount of white pigment can adversely affect the medium colors.
2.2 BATCH PROCESS AUTOMATION:
Batch processing control systems are concerned with recipe management and batch information. Batch
processing is controlled in a batch processing machine. machine used in pharmaceutical industry for the
manufacturing of Tablets, Capsules. Such machines are complicated and perform many steps which as a
group are identified as recipe for the production of product. Each time the product is run, it is known as
batch. Various process variables, such as air flow through the machine, quantity of raw material and
the temperature of environment must be controlled during the steps being performed according to
recipe for a particular product. The creation of recipe can be a difficult procedure, since experiments in
many cases need to be performed when designing each step of the recipe. Furthermore once a recipe
has been created for a particular product, it is important that the of that recipe for a particular batch.
This information is also important for management and regularity agencies that regulate the operation
of such a machine concerning the running of particular batch be safely maintained and available for

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inspection. The recipe can be created by use of editing screen of batch processing control software by
which , in a computer individual steps of the recipe are represented by graphical icons which reflect the
automatic process that the machine is to execute. A recipe matrix also provided which control element
indicates steps of process, parameter values are displayed for the control elements which correspond
with respective steps for the recipe being created. The computer has capability of switching between
the recipe editing screen and recipe matrix screen. The recipe is used to automatically operate the batch
processing machine. Management of the manufacturing companies be able to receive information
concerning the running
2.3 REASONS TO AUTOMATE BATCH PROCESS:
You have recurring problems with consistency, rework or rejected product.
You cant meet demand and must get more from your current equipment.
Costs are beyond expectations or you suspect youre leaving profits in the tank, and want to
get them out.
You face safety issues and liability exposure from manual operations.
The competition is outmaneuvering you on delivery time, product variations, quality or price.
You need to replace aging batch controls because you can not get the parts, results or flexibility
you need.
Youre tired of not having data to prove that you are and have been delivering on-spec.
You know exactly what you want to do and need an experienced, resourceful provider to
complete some or all of it.


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2.4 STANDARDS FOR BATCH CONTROL:
1. ANSI/ISA-95
2. ANSI/ISA-S88
2.4.1 ANSI/ISA-95
ANSI/ISA-95 is a multi-part, international standard for the integration of enterprise and control systems.
Lets first look at the classic S95 control hierarchy,

Figure 2.1: classic S95 control hierarchy
The above figure shows different levels of integration of enterprise for control system.
put a more practical spin on this, especially in terms of what applications or functions occur at each level

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Figure 2.2: S-95 Levels with Applications
Figure 2.2 shows example applications or functions for each level, but others can exist.
Level 4: have applications like supply chain management (SCM) or customer relationship management
(CRM).
Level 3: contain applications such as laboratory information management systems (LIMS).
Levels 1 and 2 contain your classic control systems.
Level 0: is the physical equipment.
S95 has three parts. Parts 1 and 2 provide a formal model for exchanged data between business systems
and manufacturing systems. In other words, Parts 1 and 2 deal with the interface between S95 Levels 3
and 4.

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Figure 2.3: Information Exchange Between Levels 3 & 4
Part 3 provides a definition of Manufacturing Operations Management, or the detail in S95 Level 3.
These are the activities on the shop floor that take production schedules and perform the actual work
required to manufacture products and provide visibility of production

Figure 2.4 Business planning & Logistics


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2.4.2 ANSI/ISA-S88
S88 defines hierarchical recipe management and process segmentation frameworks, which separate
products from the processes that make them. The standard enables reuse and flexibility of equipment,
and provides a structure for coordinating and integrating recipe-related information across the
traditional ERP, MES, and control domains.
The standard helps segment (modularize) processes and provide frameworks for instructions
(recipes); how much automate is up to designer and may depend on the type of process designer
trying to control.S88 is a powerful standard for sequencing any process: batch, continuous, or
discrete .
According to the S88 standard, a batch process is defined as
a process that leads to the production of finite quantities of material by subjecting quantities of input
materials to an ordered set of processing activities over a finite period of time using one or more pieces
of equipment.
S88 isnt just a standard for software, equipment, or procedures; its a way of thinking, a design
philosophy. Understanding S88 will help designer better design processes and manufacture products.
Leveraging the knowledge and experience contained in the standard will enable you to better identify
customer needs, make recipe development easier, and help reduce the time needed to reach full
production levels with a new system or for each new product.
Some people in industry have identified a handful of basic rules, or principles, on the intent of the
standard ( the intent of the committee that wrote it). So, before we go diving into some details in this
tutorial, we thought it might be helpful to toss out a few of the principles.

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(a) Principles:
Principle 1: The concept of control has a specific meaning
Well define control as an activity that makes equipment do things. Control must occur, but it doesnt
matter how:
Control can be fully manual (operator driven)
Control can be fully automatic (computer driven)
Control can be some combination of both (somewhere in between fully manual and fully
automatic)

Figure 2.5: The Concept of Control
S88 was designed to handle all levels of automation. That is, the standard can be applied to a fully-
automated system or to a completely manual systemor anything in between.
Principle 2: Separate the recipe from equipment control
The enabling ability of S88 to isolate recipes from equipment is a significant technical strength of the
standard. A recipe drives the process for making a product (or otherwise sequencing work in a non-
manufacturing application). Control drives equipment behavior, as we mention briefly above. These are
two very different activities and concepts. There is no need to think of them as one.

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Figure 2.6: Separate Recipe and Equipment Control
In a manufacturing process, if recipes are kept separate from equipment control, the manufacturing
process is more flexible and can present a more appealing scenario: engineers can specify or design
equipment control based on the full capabilities and the performance of the equipment, not based on
requirements of a product or products. Similarly, the person who manages the recipe scientists,
product specialists, or process engineers can create it and make changes to it directly.
Principle 3: Everything breaks into pieces
One of the key aspects of S88 is it enables the segmentation of processes. We can also call this the
modularization of processes. The recipe and the process are made up of smaller pieces. The recipes is
made up of concentric parts, the first level being called Unit Procedures. The process (or equipment) is
made up of modules, the first level being called Units.

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Figure 2.7: Everything Breaks Into Pieces
Its this modularization that enables both flexibility and reuse of recipe components and equipment
control components (often implemented via control systems and software).
(b)Recipe:
According to S88.01, a recipe is defined as:
The necessary set of information that uniquely identifies the production requirements for a specific
product. In other words, a recipe tells us how to combine ingredients (raw materials) using equipment
to make a product.
Recipe types:
The general recipe is used at the company level and is the basis for lower-level recipes. It defines raw
materials and their quantities, and the required processing to make the product. However, the general
recipe is usually created without specific knowledge of a particular site or the equipment that will
manufacture a produt.

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A site recipe is specific to a manufacturing site. It is usually derived from the general recipe to meet
specific conditions or constraints of the site manufacturing the product. The site recipe provides the
level of detail necessary for long-term production scheduling for a site. Site recipes might differ as to the
language in which they are written or specifications for local raw materials. While it may still not be
specific to a particular set of equipment, a site recipe may be specific to on-site processing or storage
capacity and constraints.

Figure 2.8: A Recipe Explosion

A master recipe is targeted to a processing area and is derived from either a general or site recipe.
Master recipes depend on equipment types or classes, such as a glass-lined reactor or mixing vessel.
These recipes can contain product-specific information required for detailed scheduling, such as
equipment requirements

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A control recipe is used to create a single, specific batch. It starts as a copy of a master recipe and is
modified as necessary to create a batch. The modifications may account for batch size, characteristics of
raw materials on-site (e.g., potency), or actual equipment to be used. nonetheless. Control recipes
unique to individual batches allow product tracking or genealogy to occur.
Information in a Recipe
1. Header Administrative information (recipe ID, author name, version number, revision
history, approvals, etc.) and a process summary.
2. Equipment Requirements Information about specific equipment necessary to make a
batch or a specific part of the batch. (Since general and site recipes dont usually call out specific
equipment, the requirements in these recipes are typically described in general terms.)
3. Procedure Defines the strategy for carrying out a process. That is, the procedure is really
the recipe steps or instructions provided to a control system or operator.
4. Formula Describes recipe process inputs (e.g., ingredients, quantities), process parameters
(e.g., processing temperature, ingredient transfer rate, mixing speed ), and process outputs (the
product and its quantity resulting from a single batch). Formulas can be used to distinguish
between different products or different product grades defined by the same procedure.
Recipe Procedure
The procedure explains how ingredients (raw materials) are to be combined, reacted, or
otherwise processed to make a batch. S88.01 defines two models for representing recipe
procedures:
1. The Process Model for general and site recipes. This model focuses on describing process
functionality, rather than equipment.

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2. The Procedural Control Model for master and control recipes. This model focuses on
describing the process as it relates to physical equipment.

Figure 2.9 : The Procedural Control Model
A unit procedure is an ordered set of operations that is carried to completion on a single unit.
That is, a unit procedure is a contiguous production sequence acting on one and only one unit.
Only one unit procedure is allowed to be active on a unit at any time. Multiple unit procedures
can run concurrently as part of the same procedure, as long as they are active on different units.
An operation is an ordered set of phases carried to completion within a single unit. Operations
usually involve taking the material being processed through some type of physical, chemical, or
biological change. Like unit procedures, the standard presumes only one operation is active on a
particular unit at a time.
A phase is the smallest element of procedural control that can accomplish process-oriented tasks.
Phases perform unique and generally independent, basic process-oriented functions, such as
charging an ingredient or agitating a tank. Simply put, phases are the workhorses of recipes. All
other elements (procedures, unit procedures, and operations) simply group, organize, and direct
phases.

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Recipe Example

Figure 2.10 : An candy Recipe Procedure

Figure 2.11: The Make Mix Unit Procedure

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(c) process cell
A process cell contains all of the equipment required to make batches. Sometimes the term train
is used to describe the equipment used to make a batch. A process cell may have more than one
train, and the order of equipment used to make a particular batch is called a path.
In other words, a process cell typically provides the boundaries of the equipment necessary to
make a batch. While not prohibited, paths do not usually cross process cell boundaries. A process
cell may be processing more than one batch at any given time (as long as equipment is available).
(d) Unit
Batching activities are focused on something called a unit. In other words, batch processing
occurs in units. A unit combines ingredients, performs a reaction, or otherwise adds value to your
product or interim product. Units are commonly vessels like a mixing tank or reactor, but dont
narrow your definition of a unit to just a vessel.
A unit frequently contains or operates on a complete batch of material. That is, the unit
holds the entire batch quantity at a time. While common, this is far from a mandate.
A unit may contain or operate on only a portion of a batch. It is not unusual for a batch to
be split into two or more sections, where sections can be processed in parallel with multiple
units or processed sequentially through the same unit.
A unit does not operate on more than one batch at a time. From a record-keeping point of
view, this made sense. Its hard to track batches or lots, if you combine two or more of them into
one unit.

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2.5 CONSIDERATION OF S88 STANDARD FOR BATCH PROCESS:
1. S88 is for automation superstars; S95 is for IT weenies.
2. if we put as much time into the S95 part of our site that we put into
the S88 part.
3. This site is about batch control, not enterprise-control integration. While S95 certainly
applies to batch control, its scope goes far beyond batch control.
4. Cells can be isolated for troubleshooting and repairs
5. Reduced dependence on proprietary systems and support
6. Better code control
7. More real time data becomes available
8. Consistency provides baseline for improvement
9. Adjustments can be made during process rather than holding up an entire batch
2.6 AUTOMATION OF BATCH PROCESS WITH PLC:
The manufacturers of automation equipment service providers in this field and end users on the need
and rationality of compliance with the S88.01 standard and batch tools based on it, these are :
1. Unsatisfactory reliability of personal computer(PC) platform and real time communication loop (can
be bypassed through redundancy but incures significant extra cost).
2. Poor adjustment of existing tools to the majority of small and medium sized projects.
3. Unsatisfactory time behavior of the pcs (concerning execution speed and time determinism ).
4. Too low expressive power of phase behavior model which is shown in

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A frequent need to memorize the current step on state transition for returning to the
same step, which is non-transparent low level concept, and per see a frequent source of
errors
Complicated logic of individual states which also behave as state machines
As consequence of above mentioned problems the contractors of batch process automation projects
often decide for different solution of execution of recipes on the programmable logic controllers (PLC)
platform, which are mostly over simplified and for this reason lose most of their expressive power,
offered by S88 based tools.
2.7 REQUIREMENTS FOR AUTOMATING BATCH PROCESS CONTROL WITH PLC:
Considering the starting points presented above the limitations of the target implementations platform
we have defined the following requirements the new batch process control tool should satisfy
1. The recipe should be executed on PLC and PC platform namely all real time control functions
including recipes, should be executed on PLC platforms, and on non-real time functions, such
as for example equipment editor, recipe management, batch management and archiving should
be executed on PC platform
2. Recipe should be represented by means of SFC notations or in a sort of tabular notation would
probably be easier to be implemented on the PLC platform than the graphic SFC notation, which
speaks in favor of using a table. Certain experiences from the past batch control projects with
tools according to S88 standard also made us think in this direction, when we encountered a
problem in the understanding or in the mastering of the SFC notation by operators, and we
explained the behavior of SFC recipe to them by means of table.

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3. Recipe hierarchy will have to be reduced due to the platform limitations we decided for two
recipe levels: a procedure level which contains the unit procedures and unit procedure level,
which contains phases. By leaving out the operation level we scarified some reuse and apart of
the structure we estimate that this is sufficient for the majority of real (small and medium sized)
projects where the new tool would be used.
4. The behavior of procedural control entities should comply with the S88 standard, but with the
introduction if certain model improvement. Modeling procedure of batch process offered phase
behavior is too simple and the consequences are to complex contents of individual elements of
the model.
5. States and modes propagation mechanism of batch control is one of the more complex aspects.
Therefore, a simple but efficient state propagation mechanism among procedural control
entities should be determined for this tool.
6. The tool should be designed in manner to achieve the highest possible level of probability.

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Chapter No 3
Programmable Logic
Controller (PLC)
Chapter No-3:programmable Logic controller

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PROGRAMMABLE LOGIC CONTROLLER

3.1 INTRODUCTION
In control systems there are a number of generic systems and methods which are encountered in 2all areas of
industry and technology. The most recent electricity has been used for control and earl electrical control based on
relays. It is common to use relays to make simple logical control decisions. The development of low cost system
has brought the revolution, The Programmable Logic Control.
Programmable logic controllers, also called programmable controllers or PLCs, are solid stat members of the
computer family, using integrated circuits instead of electromechanical devices to implement control functions.
They are capable of storing instructions, such as sequencing, timing, counting, arithmetic, data manipulation,
and communication, to control industrial machines and processes. A PLC is a user-friendly, microprocessor-
based specialized computer that carries out control. Programmable Logic Control is important because all
production processes go through a fixed repetitive sequence of operations that involve logical steps and
decisions.
3.2 THE ROLE OF THE PROGRAMMABLE LOGIC CONTROLLERS (PLC):
In an automated system the plc is commonly regarded as the heart of the control system. With a control
application program (stored in plc memory) in execution, the PLC constantly monitors the state of the system
through the field input devices fed back signals. It will then depend upon the program logic to determine the
course of action to be carried out at the field output devices.
Programmable controllers have many definitions. However, PLCs can be thought of in simple terms as industrial
computers with specially designed architecture in both their central units (the PLC itself) and their interfacing


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circuitry to field devices (input/output connections to the real world).Programmable logic controllers are mature
industrial controllers with their design roots based on the principles of simplicity and practical application.
Figure 3-1 illustrates a conceptual diagram of PLC applications.

Figure3.1: PLC conceptual application diagram

A PLC can b used to control a simple repetitive task or a few of them may be interconnected together with other
host controllers in order to integrate the control of complex process.
Input /Output Devices
Intelligence of an automated system is greatly depending on the ability of a PLC to read in the signal
from various types of automatic sensing and manual input field devices. Push-manual input device. On the
other hand, for detection of work-piece, monitoring of moving mechanism, checking on pressure and or liquid
level and many others, the PLC will have to tap the signal from the specific automatic sensing devices like
proximity switch, limit switch, photoelectric sensor, and level sensor and so on. Types of input signal to the

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PLC would be of ON/OFF logic or analogue.
An automatic system is incomplete and the PLC system is virtually paralyzed without means of interface to the
field output devices. Some of the most commonly controlled devices are motors, solenoids, relays indicators,
buzzers and etc .However, other output devices such as the pilot lamp, buzzers and alarms are merely
meant for notifying purpose.
3.3 PLC BASICS
A PLC consists of a Central Processing Unit (CPU) containing processor, executive memory and application
memory, Input and Output Interfacing modules, which are directly connected to the field I/O devices. The
program controls 4the PLC so that when an input signal from an input device is turned on, the appropriate
response is made. The response normally involves turning on or off an output. Signal to some sort of output
devices.

Figure 3.2: Model of PLC

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The central processing unit (CPU) governs all PLC activities. The following three components, shown in Figure 3.2
The processor
The memory system
The power supply
The previous PLC Block Diagram, illustrating its basic functionality. The control engineer (user) enters the control
program on the program loader. The program loader writes this program into the memory. The logic solver
reads the states of the sensors through the input modules, then uses this information to solve the logic stored
in the user memory (program) and also writes the resulting output states to the output devices through
the output modules.
3.4 CONSTRUCTION OF A PLC
Some PLCs are integrated into a single unit, whereas others are modular. Integrated PLCs are sometimes called
shoebox or brick PLCs because of their small size. If an integrated PLC is available with the capabilities that
a user needs .Modular PLCs consist of optional components required for a more complex control
application, as selected and assembled by the user. The Modular PLCs include the following components:
1- The CPU module, containing the CPU and its memory.
2- A power supply module, to provide power to the CPU and often to provide power to drive sensors.
3- Input and output modules (I/O modules), to allow the PLC to read sensors and control actuators.
4- A rack or bus, so that the CPU module can exchange data with I/O modules.

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A PLC sys tem with these components is all that is needed to control an automated system.
A programming unit is necessary to create the user-program and send it to a PLC CPU module's memory. The
programming unit is used to build, test and edit the logical sequence that the PLC will execute. A Network
interfaces to allow interconnect ting of PLCs and/or other controllers into distributed control.
An Operator interface devices t o allow data entry and/or data monitoring by operators.

Figure 3.3: Modular PLC I an automated sustem

3.5 PLC ATCHITECTURE:

3.5.1 The CPU Module:
The CPU module contains the central processing unit and its memory. The memory includes PROM
(programmable read-only memory) containing the PLCs operating system, driver programs, and
application programs, and RAM where the user-written programs and working data are stored.Many PLCs

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also offer removable memory modules, which are plugged into the CPU module.The user can make a copy
of the user-program and data on EEPROM (electrically erasable programmable read-only memory) chips in
the removable memory modules. Recently, PLCs have started to include flash memory. Flash memory is like
EEPROM memory except that it can be written to without needing special circuitry. Flash memory is used
on some removable memory modules instead of using the older EEPROM memory chips, but flash
memory is also sometimes built into the CPU module, where it automatically backs up parts of RAM.
The CPU of a PLC system may contain more than one processor (or micro) to execute the systems duties and/or
communications, because extra processors increase the speed of these operations. The principal function of the
processor is to command and govern the activities of the entire system.

Figure 3.4 Memory and processors in CPU of PLC

During its operation, the CPU completes three processes: it reads, or accepts, the input data from the field

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devices via the input interfaces, it executes, or performs, the control program stored in the memory system,
and it writes, or updates, the output devices via the output interfaces. This process of sequentially reading the
inputs, executing the program in memory, and updating the outputs is known as scanning.
3.5.2 THE RACK OR BUS:
During every scan cycle, a CPU module reads and writes I/O modules that are part of the modular PLC.
The CPU module is connected to each of those I/O modules via a set of parallel conductors called a bus. In
some modular systems, the bus is in a back plane circuit card in a rack, and all PLC modules are plugged
into slots in the rack. The bus does not provide power to operate the sensors or actuators attached to
I/O modules.
3.5.3 THE POWER SUPPLY:
a power supply module c converts available power to dc power at the level required by t he CPU and I/O
module internal circuitry. Usually, the available power is typically 60 Hz/120 V ac or 50 Hz/220 V ac,
although power supply modules are available for other input power characteristics. Output power must
drive the computer circuitry at 5 V dc. Power supply modules may be connected to the bus or may have to be
wired to the CPU module in modular PL systems. Some but not all power supplies include power conversion

35

Figure 3.5: The power supply in a plc system
circuitry that outputs 24 V dc via screw terminals on the power supply module. These PLCs provide only
enough power to drive a few of the sensors and actuators that are connected to I/O modules If the PLC-
based control system requires significant power to drive sensors and actuators, or needs dc levels other
than 5 or 24 V dc, or needs other electrical signal characteristics.
3.5.4 Digital I/O modules:
These are used to connect the PLC to sensors and actuators that can only be switch on and off. Modules
are available for a variety of dc and ac voltages and currents. Each module typically can be connected to
several digital sensors and/or to several digital actuators of similar electrical characteristics.
3.5.3 Analog I/O modules:
These are used to connect the PLC to sensors that can provide electrical signals which are proportional. To
a measured value or to actuators that vary their output proportionally with the electrical signals they
receive from an output analog module. A single analog I/O module can typically only be connected to a
few sensors or actuators of similar electrical characteristics.

36
3.5.4 Communication interface modules:
which are intelligent I/O modules that handle the exchange of data via a communication link. The user-
program in the CPU writes data to the communication interface module, and the module ensures that it
is placed on the communication network. Similarly, the communication interface module can accept data
from other computers via the communications network and hold it until the CPU reads it from the
module. Modern CPU modules can be connected directly to communication networks, so communication
interface modules are needed only if communications requirements exceed the CPU's built-in capabilities.
When most PLCs power up, they perform a self-check that includes searching the bus to determine how
many modules are present, in order to optimize the data exchange that will be performed each scan
cycle.
3.6 CHARACTERISTIC FUNCTIONS OF A PLC:
A programmable controller is currently defined by the National Electrical Manufacturers Association
(NEMA) as a digital electronic device that uses a programmable memory to store instructions and To
implement specific functions such as logic, sequence, timing, counting, and arithmetic to control machines
and processes. Instead of this definition it is more useful to examine the most important and essential
characteristics of a PLC that portray its unique aspects which are:
1)It is field programmable by the user. This characteristic allows the user to write and change prog-
rams in the field without rewriting or sending the unit back to the manufacturer for this purpose.
2)It contains programmed functions PLCs contain at least logic timing, counting, and memory functi-
ons that the user can access through some type of control-oriented programming language.

37
3)It scans memory and inputs and outputs ( I/O ) in a deterministic manner. This critical feature allows
the control engineer to determine precisely how the machine or process will respond to the program.
4)It provides error checking and diagnostics.
5)It can be monitored A PLC will provide some form of monitoring capability, either through
indicating lights that show the status of inputs and outputs, or by external device that can display
program execution status.
6)It is packaged appropriately PLCs are designed to withstand the temperature, humidity, vibration,
and noise found in most factory environments.
7)It has general purpose suitability Generally a PLC is not designed for a specific application, but it can handle
a wide variety of control tasks effectively.
3.7 TYPES OF PLC
Programmable controllers are available in all shapes and sizes, covering a wide spectrum of capabilities. On the
low end are relay replaces, with minimum I/O and memory capability. At the high end are large supervisory
controllers, which play an important role in hierarchical systems by performing a variety of control and data
acquisition functions. With the explosion of new products, including general and special-purpose programmable
controllers, system selection now places an even greater demand on the designer to take a system approach to
selecting the best product for each task. Programmable controller selection affects many factrs, so the designer
must determine which characteristics are desirable in the control system and which controller best fits the
present and future needs of the application.


38
3.7.1 MICRO PLCS:
Micro PLCs are used in applications that require the control of a few discrete I/O devices, such as small conveyor
controls. Some micro PLCs can perform limited analog I/O monitoring functions (e.g., monitoring a temperature
set point or activating an output). Figure shows a typical microcontroller.
3.7.2 SMALL PLCS:
Small controllers are mostly used in applications that require ON/OFF control for logic sequencing and timing
functions. These PLCs, along with microcontrollers, are widely used for the individual control of small machines.
Often, these products are single-board controllers. Table 4.2 lists the standard features of small PLCs.
3.7.3 MEDIUM PLCS:
Medium PLCs are used in applications that require more than 128 I/O, as well as analog control, data
manipulation and arithmetic capabilities. In general the controllers in segment 3 have more flexible hardware
and software features than the controllers previously mentioned.
3.7.4 LARGE PLCS:
Large controllers are used for more complicated control tasks, which require extensive data manipulation, data
acquisition, and reporting. Further software enhancements allow these products to 8perform complex
numerical computations.
3.7.5 VERY LARGE PLCS:
Very large PLCs are utilized in sophisticated control and data acquisition applications that require large memory
and I/O capacities. Remote and special I/O interfaces are also standard requirements for this type of controller.
Typical applications for very large PLCs include steel mills and refineries. These PLCs usually serve as supervisory
controllers in large, distributed control applications. Selecting the right programmable controller for a machine

39
or process involves evaluating not only current needs, but future requirements as well with proper planning,
future memory expansion may only require the installation of a memory module; furthermore, the addition of a
peripheral may be as easy as connecting the device to the communication port.
3.8 DESCRIPTION OF THE PLC SOFTWARE:
3.8.1 Operating System and Application Programs:
The CPU module of a PLC comes with a very different operating system program than those used in most other
computers, and comes complete with application programs programmed into the CPU's memory. The
operating system program causes the PLC to start when power turned on, to run the user-program when the
PLC is switched into run mode, and to respond to the user commands by running the appropriate application
programs.
The application programs allow the user to enter programs and data into the PLC's memory. Some Parts of the
user accessible memory are retained even when the PLC's power disconnected. The PLC operating system
makes the PLC run user-programs very differently from the way other computers run user-programs. A PLC
operating system executes an initialization step once each time it is put into run mode, and then repeatedly
makes the PLC executes a scan cycle sequence as long as the PLC remains in run mode. Every time the PLC
finishes one scan cycle and starts an other, the operating system also restarts a watch dog timer. The
watchdog timer runs while the scan cycle executes. If the watchdog timer reaches it pre-set value before
being restarted (if a scan cycle takes unusually one to complete), the PLC will immediately fault, and
stop running .After faulting, the PLC usually needs operator intervention before it can resume running.
3.8.2 PLC User-Programs:
User programs are not part of the preprogrammed set of program purchased with t he PLC. They

40
must be entered into a PLC's RAM memory by a programmer using a programming unit, which
can then be disconnected from the PLC. PLCs save user-programs in memory that is either unaff-
ected by power loss or is maintained by a long-life battery. The us er-program remains in
the PLC's memory until a programming unit is used to change it.
3.8.3 PLC Languages:
The PLC language standardized by IEC consists of two illustrated languages, two character languages
and SFC.
1.Illustrated languages
a)LD (Ladder Diagram):It is a graphical language based on the relay ladder logic.
b)FBD (Function Block Diagram):It is a graphical language for depicting signal and data flows
through function blocks - re-usable software elements.
2.Character language
a)IL (Instruction List):It is a low-level 'assembler like' language based on similar instruction list languages.
b)ST (Structured Text):It is a high-level language of PASCAL type.
3.SFC (Sequential Function Chart) It is a graphic al language for depicting s equential behavior of a
control system. It is used f or defining control sequences that are
time and event-driven.

41
3.9 PLC PROGRAMMING:
LADDER LOGIC
Ladder logic includes:
"Ladder" diagrams
Digital logic functions
3.9.1LADDER DIAGRAMS:
Ladder diagrams are specialized schematics commonly used to document industrial control logic
systems. They are called "ladder" diagrams because they resemble a ladder, with two vertical rails
(supply power) and as many "rungs" (horizontal lines) as there are control circuits to represent. If we
wanted to draw a simple ladder diagram showing a lamp that is controlled by a hand switch, it would
look like this:

Figure 3.6 manually switch controlling of lamp

The "L
1
" and "L
2
" designations refer to the two poles of a 120 VAC supply, unless otherwise noted. L
1

is the "hot" conductor, and L
2
is the grounded ("neutral") conductor.


42
3.10 SPECIFICATION OF DELTA DVP-SS:
The plc we are using in our project is dvp SS series The DVP-SS series provides a 14-point Main
Processing Unitand allows to expand units with 8~16 points. The maximum input/output points could be
extended up to 128 points. Since the power supply unit is independent of the main unit, and with the
volume of the device being smaller, the installation of DVP PLC is thus easier.This is an OPEN-TYPE
built-in PLC, and the PLC is certified to meet the safety requirements of IEC 61131-2RS(UL 508) when
installed in the enclosure to avoid high temperature, high humidity, exceessive vibration corrosive gases,
liquids, airbome dust or metallic particles. Also, it is equipped with protective methods such as some
special tool or key to open the enclosure, to avoid the possible hazard to users or any damage to the PLC


43

Figure 3.7 : Product profile and outline
3.10.1 Wiring and Specifications of the Power Terminals:
This PLC model uses DC input power. Therefore, make sure that PLC is connected to terminals 24VDC
and0V (power range 20.4VDC~28.8VDC) when the power is ON. PLC will stop the operation and
output will be OFF whenever the power input is lower than 20.4VDC. Consequently, the ERROR LED
will blink swiftly.

44

Figure 3.8: Wirring of Power Terminal

3.10.2 Wiring of the Input Point:
Two types of wiring: SINK or SOURCE, depends on the way of configuration the DC input signal to the DC input
power in, which are defined as follows:
The DC Type, there are two types of wiring to the DC type: SINK and SOURCE

Figure 3.9 : input/outpot wirring

45
3.10.2 The PLC I/O Response Time:

The total response time of the PLC from the input signal to the output motion is calculated as follows:
Response Time = input interface delay time + users program scan time + output motion delay time

Table 3.1 Response time of PLC

3.10.3 The basic commands and the application commands

The basic commands and the application commands of the MPU of this series are totally applicable to the DELTA
DVP-PLC ES Series MPU.
The DVPHPP hand-held programming panel, the DPLSoft (the DOS version) ladder diagram editing program or the
WPLSoft (the Windows version) ladder diagram editing program are all good for use with the DELTA or the
WPLSoft (the Windows version) ladder diagram editing program are all good for use with the DELTA.


46
FUNCIONAL SPECIFICATIONS:

Table 3.2 Plc specifications

47
Chapter No 4
WPL Software
(Ladder Logic Software)
Chapter No -4:WPL Software

48

4.1 INTRODUCTIONS AND SYSTEM REQUIREMENT
WPLSoft is a program editor of Delta DVP series PLC for WINDOWS computers. In
addition to general PLC programming and WINDOWS editing functions (e.g. Cut, paste,
copy, multi-window display, etc.), WPL Soft also provides various comment editing as well
as other special functions (e.g. register editing and settings, file accessing and saving,
contacts monitoring and setting, etc.).
The following system requirement are must to install WPL software
Windows 95/98/2000/NT/ME/XP/VISTA operating system.
Pentium 90 and above CPU.
128MB or above (256MB and above is recommended) memory.
Capacity: 50MB or above hard disk.
CD-ROM drives (for installing WPL Soft.
At least one of COM1~COM8 connected to PLC RS-232.

Figure 4.1 WPL soft


49
4.2 INSTALLATION AND PROGRAM EXECUTION:
WPLSoft will be installed in the default directory
C:\Program Files\Delta Industrial Automation\WPLSoft x.xx". Double click WPLSoft icon
to execute the program. The WPL editor window will pop up, There are File , View,
Communication, Options and Help in the toolbar when executing WPLSoft for the first time.

Figure 4.2 opening Window
Title bar: Displaying file name.
Menu bar: There are ten items in menu bar: File, Edit, Compile, Comments, Search, View,
Communication, Options, Window, and Help.
Toolbar: Selecting editing tools by clicking icons directly. There are four types:
1. Standard Toolbar:

2. PLC Toolbar:


50

3. Ladder Toolbar: (display in ladder diagram mode)

4. SFC Toolbar: (display in SFC diagram mod)

5. Debug Toolbar(display in simulator debug mode)

Working area : The area for designing and programming. Users can choose Instruction
editing, Ladder edition or SFC editing as their custom setting.
Status row: Displaying messages, including replace/insert mode, coordinate, PLC scan time,
program size after compiling, Communication indicating LED (blinking during
communication), PLC status (RUN/STOP/HALT/ ERROR), PLC COM port number(baud
rate), PLC models, etc.

4.3 SETUP
After executing WPLSoft, users can open a new file for PLC program design. Program titles,
PLC Type, program capacity (refer to the specification of PLC model name and program
capacity) and file name can be set in Select a PLC Model window.

When the above setting is finished, 2 sub windows will pop up. One is Ladder Diagram
Mode and the other is Instruction List Mode. Users can choose their favorable editing mode
for programming PLC instructions.

51

Figure 4.3: Modes of Programming

4.4 LADDER DIAGRAM MODE:
Start up WPLSoft, and click New to create a new screen or click Open to open an old
file. Then, users can enter into the editing environment of ladder diagram mode There is a
ladder diagram toolbar shown on the top of the ladder diagram mode window. To create and
edit a ladder diagram, you can click the icon on toolbar directly or move the editing block to
the proper position and enter instructions.

Ladder diagram

Figure 4.4 : Example Ladder Diagram

Ladder Diagram Mode
Instruction List Mode

52
4.4.1 Operation Steps of Editing the Ladder Diagram:

Table 4.1: Editing the Ladder Diagram
After the ladder diagram is completed, you can compile and convert the completed ladder
diagram to instruction codes and SFC diagram.
4.4.2 Ladder Diagram Editing Instructions
WPLSoft provides several brevity codes for yours to input basic Instructions more quickly
and conveniently when editing a ladder diagram.

Table 4.2: Shortcuts For Editing


53

4.5 INSTRUCTION MODE:
Instruction editing environment looks like this

Figure 4.5: Instruction Mode Window
Type a complete PLC instruction when entering instruction mode.
Input Operation Example
Instruction programrefer to the following table and input instructions
(0000) LD X1
(0001) OR M0
(0002) OUT Y1
(0003) MOV D1 D2
(0008) END

After an instruction program is completed, it can be converted to the ladder diagram and SFC
diagram through compiling.


54
4.6 EDITING COMMENTS:
In the ladder diagram mode, there are three operating modes for editing comments: Device
comments, Segment comments and Row comments. However, while in SFC mode and
instruction mode, only EditDevice Comments function is provided.
Edit Device Comments:

Figure 4.6 Edit device Comment Window

4.7 COMMUNICATION:
Before proceeding with the communication, please make sure that PC COM port (RS232)
and PLC COM port has connected successfully. WPL Soft provides various tools for
operations, such as device monitor, read/write register data to PLC, modem connection,
communication setting, etc. It is convenient for users to edit, monitor or test by WPL Soft.
Click Options > Communication Setting
When communication setting is completed, users can start to read the PLC internal program
according to the following procedures
Click Communication To read data and retentive range from PLC, select PC <= PLC
under the Communication Mode when the transfer setup window appeared. Select Device
Comment in dialog, if PLC supports saving device comment.

55
4.7.1 Write PLC:
1. Users can transmit a new program to PLC by clicking Communication > Transfer
Setup or click icon on toolbar or using keyboard shortcuts (Ctrl) + (F1).
2. To write data into PLC, select PC => PLC under the Communication Mode when
the transfer setup window appeared. Decide the write-in content by checking the boxes of
device comment, password, retentive range, default value, and RTC.
3. After clicking OK, there could be a Password Setting window if the PLC requested a
password. Users are allowed to read the internal program once with correct password.
However, an error message will appear with wrong password.
4. WPLSoft will transmit the PLC program from the start to the first END instruction
and write the program into PLC.
4.7.2Verify with PLC:
The function can verify the PLC internal program with the editing program in WPLSoft. If
the WPLsoft editing program is different from the PLC program, WPLSoft will send a
warning message of Verification error!! (as shown below), and if the two programs are the
same, WPLSoft will send a message of Verification is completed!!
Run/Stop PLC Click Communication > Run or click on the icon to get the dialog,
then press Yes to set the PLC in RUn
Click Communication > StopN condition or click on the icon to get the dialog, then
press Yes to set the PLC in STOP condition.


56
4.7.3:Communication Auto-Detect
WPLSoft editor can auto-detect the PLC communication speed.

Figure 4.7: auto-detect the PLC communication
4.8 SFC EDITING ENVIRONMENT:
SFC (Sequence Function Chart) is one of the programming languages defined in the IEC
61131-3 Standard and is also one kind of the diagram editing mode. However, the whole
structure of SFC diagram looks like a flow chart. In fact, it is to utilize the Step Relay S
within the PLC.
Start up WPLSoft and click File > New to create a new screen or click Open to open
an old file. Then, users can enter into the editing environment of SFC.

Figure 4.8 sequential function chart editor

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4.8.1 Basic Operation

Table 4.3: SFC Editing
4.8.2 SFC Editing Environment: In SFC mode, up to 16 columns (horizontal direction) can
be used for programming, whereas there is no limit of the rows (vertical direction). Every
dotted cell stands for one SFC symbol, and therefore, a maximum of 16 columns could be
displayed on the screen in the horizontal direction at the same time.

58

Figure 4.9 SFC Environment
4.8.3 SFC Editing Instruction
Convert SFC Diagram into Instruction Codes through Compiling: (If users want to display a
ladder diagram, the SFC diagram needs to be compiled into instruction codes and then
compiled again into the ladder diagram.)
1. The SFC diagram is compiled to instruction codes .
2. The instruction codes are compiled to the ladder diagram

Figure 4.10 SFC Editing Instruction

WPLSoft supports 3 monitor modes to be run simultaneously: SFC mode monitor, 2. Ladder diagram
monitor, 3. Device monitor

59
4.9 SIMULATOR:
The simulator provides users the program testing function without connecting with PLC.
However, the actual result might not be completely the same as connecting with PLC. The
program should be tested on PLC before running in field applications.
When simulator is activated, the WPLSoft window will be shown as below. The icons in the
frames are simulator functions.

Figure 4.11 ladder monitoring

When simulator is activated, users can perform communication functions such as monitoring,
program download/upload without setting the communication interface first. The operating
mode is same as the actual PLC connecting situation.
4.8.1 Simulator icons:


60
4.8.2 Introduction to the Debug mode
Click icon on toolbar to start debug mode. Users can switch between Message area and
Debug Mode Monitor Devices area from bottom:

Figure 4.12 Debug Mode
4.8.3 Functions of Debug Mode:
1. WPLSoft will write the program into simulator when debug mode is activated. In
addition, the scan time will be fixed and set to 100ms. Users can also set the scan time by
D1039 according to the approximate actual scan time of PLC. In debug mode, users can
set several break points in ladder diagram mode and instruction mode. The program will
stop at the break point when executing Scan Run.
2. In ladder diagram mode, right-click to set the break point on the instruction pointed by
cursor. After setting, there will be a red dot on the left of instruction.

3. In instruction mode, break points can be set by right-clicking as in ladder diagram
mode, and the instruction with break point will be highlighted by red color.

61

4. In debug mode, there is a window of Debug Mode Monitor Devices area in addition to
message display area. Users can monitor the status and values of devices, set the devices
to force On/Off or change present values.

The run time of timers and counters could differ according to the efficiency of users PC. The
working behavior of timer is same as ES/SA series PLC.

62
Chapter No 5
INSTRUMENTS &
DEVICES
Chapter No-5:Instruments & Devices

63
5.1 PRESS CONTROL:
Press control is a device with a new concept that guarantees optimal control of pumps for
home and industrial use. Deriving from a hydraulic and electronic logics project, it is capable of
simultaneously detecting both the pressure the flow, as well as automatically managing the
pump operation. It replaces the traditional expansion tank system, protecting the pump in the
case of water shortage.
Far more compact than traditional system, it is totally reliable, resistant, and easy to install.

Figure 5.1: press control

5.1.1 Applications and Performance:
Replaces the traditional expansion tank system.
Starts and stops the pump in accordance with the opening and closing of traps.
Maintains constants pressure during delivery.

64
Stops the pump in case of water shortage, protecting it from dry running.
Attenuates the effects of water hammering, and maintenance-free.
5.1.2 Technical Features of press control:
Monophase power supply voltage 230V
Acceptable voltage variations 10%
Frequency 59-60 Hz
Maximum current 16(8)A
Maximum power 1.5 kW(2hp)
Maximum operating pressure 10 bar(1MPa)
The electronic board accepts minimum voltage variation of 207 V and maximum variation of
253 V with frequency of 50-60 Hz
It supports a rated current for resistive loads of upto 16A,and a rated current for inductive loads
of upto 8 A.
It is capable of controlling a mono phase motor with a maximum power of 1.5 kW equivalent to
2 HP.
For hydraulic parts standard establish that device must
Resist for 1 minute with out any visible loss of pressure equal to twice the maximum
operating pressure (20 bar).

65
It must also be demonstrated that the device can release a pressure equal to four times
of the maximum operating pressure (40 bar) without dropping in such away as to be
hazardous for humans.
5.1.3 Using press control with PLC:
In particular, the tests control the following by means of a PLC
Watertight sealing at maximum pressure and therefore the absence of Leaks.
Staring and stopping the pump.
The intervention value of the pressure gauge (restarting).
The value of the minimum flow below which the flow switch stops the pump.
5.1.4 Components of press
contr

66
Figure 5.2: Component of press control
5.1.5 Installation
The device can be mounted either directly onto the pump and the first tap.
If the input pressure of thr device exceeds 10 bar (1 Mpa), install a pressure reducer
between the pump and the device itself.
No tap must be mounted between the pump and the device.
It is recommended to connect the output of the device to the plant by means of a ball
valve and flexible tube (fig. B).
Before starting the device check that the pump is correctly primed.

Figure 5.3: Installation of pres control


67
5.1.5 Electrical wiring:
It is recommended to always foresee the installation of omnipolar switch with minimum
opening of the contacts, equal to three millimeters, upstream from the device.
The monophase pumps (230 V) with motor power of up to 1.5 kW (2 HP) can be connected
directly to the device, whereas the same pumps with powers exceeding 1.5kW (2 HP), and all
the three-phase pumps (400 V). must be connected to the device by means of remote control
switch.

Figure 5.4: Electrical wiring of press control


68

5.2 THREE PHASE INDUCTION MOTOR:
The three-phase induction motor, also called an asynchronous motor, is the most commonly
used type of motor in industrial applications. In particular, the squirrel- cage design is the most
widely used electric motor in industrial applications.
5.2.1 Principles of Operation
The electrical section of the three-phase induction motor as shown in Figure 1.2.2 consists of the
fixed stator or frame, a three-phase winding supplied from the three-phase mains and a turning
rotor. There is no electrical connection between the stator and the rotor. The currents in the
rotor are induced via the air gap from the stator side. Stator and rotor are made of highly
magnetizable core sheet providing low eddy current and hysteresis losses.
5.2.2 Stator:
The stator winding consists of three individual windings which overlap one another and are
offset by an electrical angle of 120. When it is connected to the power supply, the incoming
current will first magnetize the stator. This magnetizing current generates a rotary field which
turns with synchronous speed ns.For the smallest pole number of 2p = 2 in a 50 Hz circuit the
highest synchronous


69
speed is ns = 3000/min-1. Synchronous speeds in a 50 Hz circuit are shown in Table 5.1
5.2.3 Rotor:
The rotor in induction machines with squirrel-cage rotors consists of a slotted cylindrical rotor
core sheet package with aluminum bars which are joined at the front by rings to form a closed
cage.The rotor of three-phase induction motors sometimes is also referred to as an anchor. The
reason for this name is the anchor shape of the rotors used in very early electrical devices. In
electrical equipment the anchor's winding would be induced by the magnetic field, whereas the
rotor takes this role in three-phase induction motors.

Table 5.1: Typical synchronous speeds in a 50 Hz circuit
Synchronous speeds are 20% higher in a 60 Hz circuit

Figure 5.5: closed squirrel-cage three-phase motor

70
The stopped induction motor acts like a transformer shorted on the secondary side. The stator
winding thus corresponds to the primary winding, the rotor winding (cage winding) to the
secondary winding. Because it is shorted, its internal rotor current is dependent on the induced
voltage and its resistance. The interaction between the magnetic flux and the current
conductors in the rotor generates a torque that corresponds to the rotation of the rotary field.
The cage bars are arranged in an offset pattern to the axis of rotation in order to prevent torque
fluctuations (see Figure Forms of squirrel-cage rotor windings). This is called "skew".
At idle the rotor almost reaches the synchronous speed of the rotary field, since only a small
counter-torque (no-load losses) is present. If it were to turn exactly synchronously, voltage
would no longer be induced, current would cease to flow, and there would no longer be any
torque.
During operation the speed of the rotor drops to the load speed n. The difference between the
synchronous speed and the load speed is called slip s. Based on this load-dependent slip s, the
voltage induced in the rotor winding changes, which in turn changes the rotor current and also
the torque M. As slip s increases, the rotor current and the torque rise. Because the three-phase
induction motor acts like a transformer, the rotor current is transformed to the stator side
(secondary side) and the stator supply current changes essentially to the same degree. The
electrical output of the stator generated by the power supply is converted via the air gap into
mechanical power in the rotor. The stator current therefore consists of two components, the
magnetization current and the actual load current.


71
5.2.4 Slip:
The difference between the synchronous speed ns and the speed n in rated operation is called
slip s and is generally expressed in percent. Depending on the size of the machine, in rated
operation it is roughly 10 to 3%. Slip is one of the most important characteristics of an induction
machine.

Figure 5.6: Rotor voltage UR is a proportional function of slip s

72
. A rotor voltage of 10% corresponds to a slip of 10% The induced rotor voltage UR as shown in
Figure is proportional to the slip s. In the stopped position, it peaks at n = 1 and s = 1, which also
results in the strongest current flow. This fact is confirmed in real-life applications by the high
starting current (starting current inrush). The torque also peaks during the stop period at a
certain rotor resistance. This behavior can be modified by design variation. However the rotor
resistance is not usually used for this purpose. The
following formula applies to the rotor speed:

5.2.5 Operating characteristics
Operating characteristics are a graphical presentation of the behavior of:
speed current
power factor power
efficiency slip

73

Figure 5.7: Operating characteristics of an induction motor as a function
n = speed ns = synchronous speed
P1 = power input P2 = power output
= efficiency cos = power factor
I = current input In = rated current
s = slip Pn = rated power
n The speed n decreases only slightly as load increases.
s Slip s increases roughly proportionally as load increases.
cos The power factor cos depends largely on load and it peaks typically during overload.
Efficiency exhibits a relatively flat characteristic and is almost constant above half-
load. It generally peaks below the rated power Pn.
I Current I increases proportionally beginning roughly at half-load. Below half-load it
decreases only slowly until it becomes the no-load current IO.

74
P The power P1 increases roughly in proportion to load starting from the no-load power.
In the overload range it increases slightly faster since losses also increase faster.
Since the efficiency and power factor cos can have a major effect on the economic efficiency
of a motor, knowledge of the partial load values is very important. Both values determine the
economic efficiency during operation. In the partial load range they both drop. In addition, in
low-speed motors the power factor cos is smaller than in high-speed motors. Therefore
closely sized, high-speed motors are not only less expensive purchase, but they also cost less to
operate.
5.3 FREQUENCY INVERTER:
The Fuji-FVR- k7s family of adjustable frequency AC drive controllers is used for controlling three
phase asynchronous motors. The inverter input is single phase or three phase and the out is
three phase. Power wiring to the motor must have the maximum possible separation from all
other power wiring. Whether from the same drive controller or other drive controllers, do not
run in the same conduit. This separation reduces the possibility of coupling electrical transient
from power circuit into control circuit or from motor power wiring into other power wiring.
Use metallic conduit for all drive controller wiring. Do not run control and power wiring in the
same conduit. All inductive circuits near the drive controller such as relay and solenoid valves
with noise suppressors or connect them to a separate circuit. When more than two drive
controllers are installed in parallel on a common power supply voltage, regardless of voltage
rating, individual line per drive controller is recommended. The drive controller is sensitive to
the amount of capacitance present on the output power conductor. Excessive capacitance can
cause an over current trip.

75
5.3.1 Three Phase Circuit Diagram:

Figure 5.8: Circuit Diagram of Inverter

5.3.2 Wiring diagram:

Figure 5.9 circuit configuration
R
S
T
Power supply
I2
I3
I1
Frequency
setting
FW
RE
X
X
RS
C
CIRCUIT
CONFIGURATION
IM
Frequency
FM
C
FM
C
FVR-K7S

76
I1,I2,I3 Correctly connect to a 10Kohm potentiometer. The wrong connection of terminals I1
and I3 will reverse the speed adjustment. Both terminals I3 and GND are ground of +5V.
FWD Terminals for clockwise operation.
REV Terminals for counter clockwise operation. Change any two phase of terminals
Free Run Inverter will stop outputting immediately after having the two terminals
shorted, and the motor will free run to stop.
X2, X3 Exterior 2nd and 3rd speed terminals. Well preset the parameters for normal
operation.
RESET terminal for releasing the protection status. Do not reset the inverter when high speed
operating.


77
5.3.2 Specification of frequency inverter:

Table 5.2: specification of inverter


78
5.4 PNEUMATIC VALVE:

Figure 5.10: Pneumatic Valves
In pneumatic systems power is transmitted and controlled through the gas under pressure with
solenoid valves. Pneumatic valves are used for increasing temperature by opening inlet valve for
steam. These valves are used as inlet valves for water and outlet valves for draining. Used for
air, neutral gas or lubricants operated at 24Vdc. We have used N.C pneumatic valve. For e.g. in
Filling routine we want to fill the tank so from PLC we give the digital output and valve will be
open. Then from level sensor output the valve is again closed.
5.4.1 Specifications:
1) Operating pressure: 0 - 0.8MPa, 0 - 1.6MPa
2) Minimum control pressure: 0.3MPa
3) Control : neutral gas, air, lubricants etc

79

5.4.3 Features:
1) open / close position of valve
2) The external pneumatic pilot could increase the service life 1,000,000 times without leakage.
3) Automatic regulating of the sealing property between the valve seat and valve to increase
sealing ability.
4) Valve body angle seat structure implements a larger flow compared to common valves;
structure is compact and with fast response
5) Seal material: long life USA Park sealing ring and PTEF V-ring and sealing pad
6) Stainless steel valve body material.
7) During installation, the control head executing device could rotate for 360 degrees in any
direction to install the joining pipe.
8) High temperature resistance, corrosion resistance and no water hammer impact.
5.5
A thermocouple is made of a pair of wires of different metals, such as iron and copper, whose
ends are welded together. The welded point is called the "junction". When the junctions are at
different temperatures, as shown in Figure 1, the thermal electromotive force (emf, millivolt) is
generated between them. By measuring the emf, we know the temperature difference A pair of
junctions between two dissimilar metals generates emf when they are at different
temperatures. This phenomenon is called the seebeck Effect. The emf depends on the

80
combination of dissimilar metals and temperature difference between the junction. However, it
does not depend on the shape of the wires and volume of metals used. The emf can be
measured with a meter in the circuit.

Figure 5.11 Thermocouple
5.5.1 Kinds of Thermocouples:
Normally seven different thermocouples are used. There are about ten thermocouples listed in
the international (IEC) and/or national standards, like ANSI of the U. S. A., DIN of Germany and
JIS
of Japan. The listed thermocouples are recognized as reliable in research and application, among
possible combinations of dissimilar metals.
A thermocouple is identified by the Type, for example Type B or B thermocouple. The positive
and negative wires identify the polarity of the thermocouple. When the hot junction is higher in
temperature than the cold junction, a positive emf appears on the positive wire.

81
A thermocouple can be used above the recommended temperature range, up to the upper
temperature limit. Above the recommended range the life of the thermocouple becomes short,
due to oxidation, crystallization of the wires and other reasons. In some applications, the only
possible, economical way of temperature measurement is to use a thermocouple near the
upper temperature limit, replacing it frequently. There are new thermocouples, like Type N
(nicrosil/nisil) thermocouple, which are expected to have a longer life than Type K
thermocouples in an oxidizing atmosphere. DIN includes Types U and L. In the U. S., Type W is
used in very high temperature (up to 2300C or 3700F).
The standards carry the temperature-emf tables of each thermocouple, referenced to 0C
(32F).In other words, it is the emf when the cold junction is at 0C
5.5.2 Selection of Thermocouple:
Choose your thermocouple based on the temperature range and accuracy required. Some
thermocouples, for example Type B and R, use expensive materials - platinum and
rhodium.
Some thermocouples generate only low emf at a low temperature range.
(1) Application temperature
Some may think that the higher the temperature range, the better the thermocouple. If you
choose your thermocouple type only by the high recommended temperature range and the
upper limit, it may be expensive, or you may find unexpected error at a low temperature.
Choose the thermocouple whose recommended temperature range agrees with the
temperature that you would normally measure in your application.
(2) Environment

82
Choose the wire materials which withstand the aggressive application atmosphere
(oxidation,
corrosion and others). A thermo-well is usually used to protect a thermocouple,
mechanically
and environmentally.
(3) Accuracy
Choose the thermocouple whose accuracy class meets your required accuracy
5.6 Temperature Transmitter:
When there is change in temperature the resistance of the thermocouple is changed and
there is very minute change in voltage, which is round about 0 to 20mA. This small
voltage is very minute to be sensed by PLC so in order to have a sensing voltage level we
use temperature transmitter, which converts the resistance into current of 4 to 20 mA.

Figure 5.12 : Temperature Transmitter


83
These transmitters are the microprocessor-based controllers combine a high degree of
functionality and reliability.
These controllers also provide extra features such as
Motor Position Control
Phase angle Power Control
Set point Programming

84
Chapter No 6
DESIGN &
IMPLIMENTATION
Chapter No-6:Design & implementation

85
6.1 CONTROLLER PHILOSOPHY
The controller is designed to be multi-tasking. It can perform more than one task at a
time, for instance A57CSTD can heat the machine on a gradient whilst simultaneously
Dosing the chemicals from the Addition Tank. The following are the functions which are
used in batch processes.
Problem Recipe:

Figure 6.1: Recipe Chart


86
6.2 MAIN FUNCTIONS TO AUTOMATE:
6.2.1 FILLING
It performs filling of the tank. The water entered in the machine is being added at the
water consumption. The main pump is off. We will control the pneumatic valve through
PLC when the valve is open water will start entering into the main vessel.
6.2.2 DRAINING
It performs the normal draining of the batch. The main drain valve is open during this
function. The function sets off the previous temperature control.
6.2.3 HEAT
It performs the normal heat-cool of the bath by the heat exchanger system. The desired
water temperature should be programmed for the water.
6.2.4 HOLD TIME
It performs to control various parameter for desired time.
6.2.5 STIRRING
This function performs to control speed of mixing by means of controlling frequency by
an inverter that is connected with motor.


87
6.3 PROJECT DIAGRAMS:
6.3.1 BLOCK DIAGRAME:

Figure 6.2: Block Diagrame project
6.3.2 MODEL DIAGRAM:

Figure 6.3: Model Diagrame

88
6.3.3 PROCESS FLOW CHART

Figure 6.4: process Flow Chart
6.4 IMPLEMENTATION OF FUNCTIONS:
6.4.1 start Filling The batch Tank
Push button is attached with input terminal X1 of PLC input terminal. As this button is
pushed valve attached with tank 1 containing parameter to be loaded is opened. In
filling functions we have to fill the parameter 1 into the tank up to the desired time . The
timer function is used .. After 1 minute valve will be closed and stop the parameter 1 to
be loaded into the tank. When stirrer will stop to move pump will be on by PLC signal
and remain on for 1 minute to fill the main batch tank.


89
CODE:

6.4.2 Heating
In heating function we increase the temperature of the tank up to the desired value by
means of heating device. The temperature sensor (Thermocouple) is used, its output
resistance is changed by sensing the temperature change, and the temperature transmitter
converts the temperature change into the current (4-20mA). The current is applied to the
PLC analog input (D110-D113), which accordingly generates the digital value. By the
compassion of digital value the PLC decide whether the heating device is on or off. we
have set two different temperature 30 c and 70 c. on reaching 30 c motor will start to
move. On 70c drain valve will be open.
The temperature output is given to PLC analog input which converts the analog value
into the digital and we will compare this digital value to the required temperature result is
true compare command will set M12 and motor at y0 will start to run.


90
CODE:

6.4.3 Stirring
For start stirring functions we have to control the 3-phase motor of 5 hp, which
is controlled through frequency inverter for the forward or reverse direction in
which motor run at constant frequency according to the requirements. The
stirrer will remain in process in constant time after that time the timer will
turened off the stirrer by means of frequency invertor through PLC.
CODE:


91
After reaching the temperature up to 30 c stirrer will start to move at 300 Hz
frequency.y0 out will remain on for 5 Minute y0 will reset. Stirrer will stop to move.
6.4.4 Drain
when temperature reaches to 70 c drain valve will open for 2 minutes.

Chapter No 1: Automation

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