Project on PLC (SILO)

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This is a project on Automatic Drum Filling System controlled by a Micrologix series PLC from ABB, Rockwell.

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Project on PLC (SILO)

  1. 1. INSTITUTE OF AUTOMATION AND TECHNOLOGYDA-74, 2ND Floor, Salt lake City, Sector-I, Kolkata-700064 Jul, 31, 09Aug, 1, 09A PROJECT ON PLCAutomatic Drum filling systemCO-ORDINATOR:DEVELOPERS:Ms. Nilanjani Mandal Sayan Chakraborty Dibyendu MandalAbhishek Chakraborty <br /><ul><li> ADVANCE d </li></ul>All of us, working in this project, are highly indebted to our teacher Ms.Nilanjani Mandal of Institute of Automation & Technology (IAT) for the amount of effort she put along with us to take the project for completion. She explained in detail the logic diagram of the system (known as “AUTOMATIC DRUM FILLING SYSTEM”) and gave us very valuable guidance throughout our project. It would have been really difficult without her help to develop this project. We, the students, along with our madam, had a very long discussion about the mechanical construction of the machine and gradually come up with a nice design. We hope everyone likes this project.<br />Thanking everyone for their co-operation.<br />Industrial Automation is the use of Control Systems to control Industrial Machinery and Processes, reducing the need for human intervention. This made the production rate constant and almost error free.<br />If we compare a job being done by human and by Automation, the physical part of the job is replaced by use of a Machine, whereas the mental capabilities of the human are replaced with the Automation. The human sensory organs are replaced with electrical, mechanical or electronic Sensors to enable the automation systems to perform the job. For example, a grinding wheel driven by a human can be replaced by a motor (which is a machine). But starting and stopping the grinding, which were done by the human by ‘looking at’ the output, will be replaced by the control of the motor by Automation.<br />With the invention of PLCs process controlling became much easier, and production rate increased noticeably. <br />Programmable (Logic) Controller or PLC is a type of computer commonly used in commercial and industrial control applications. <br />The prominent manufacturers of PLC are Allen-Bradley (Rockwell), Siemens, GE Fanuc, Schneider Electric, Mitsubishi, etc. <br />Our aim in this project is to build a Automatic drum filling system using PLC[Allen-Bradley (Rockwell)] so that each drum contains exactly equal amount of fluid and the output rate can be configured by the user.<br />Design a ladder control circuit which will automatically position and fill the drums which are continuously sequenced along the conveyor. Ensure that the following details are also met:<br />The sequence can be stopped and re-started at any time using the panel mounted Stop and Start switches. <br />The RUN light will remain energized as long as the system is operating automatically.<br />The RUN light, Conveyor Motor and Solenoid will de-energize whenever the system is halted via the STOP switch.<br />The FILL light will be energized while the drum is filling.<br />The FULL light will energize when the drum is full and will remain that way until the box has moved clear of the level-sensor.<br />A regulator should select total number of drums to be filled. [A=100, B=200, C=300]<br />A numeric display should display the total number of drums to be filled in the “Input section” and another numeric display should display the total number of drums already filled in the “Output section”.<br />Process simulation SCADA diagrams<br />FIG1<br />Initially the drum is at rest until the start button is pressed. The regulator is fixed at point A indicates that the system will stop automatically after filling 100 drums. [It will fill 200 and 300 drums in B and C mode respectively. RESET button is to clear counter.]<br />If start button is pressed the “MOTOR” will start and “RUN” light will glow until the “STOP” button is pressed.<br />When drum appears above the “PROXIMITY SENSOR”, motor stops and filling process starts.<br />During the filling process when solenoid valve opens the “FILL” light will glow.<br />When filling is complete and sensed by “LEVEL SENSOR” the “FILL” light goes off closing the valve. “FILL” light will glow simultaneously and off immediately, and the “MOTOR” will start again.<br />Fig2<br />The system is in run mode but motor is not running as the proximity sensor output is true. <br />Solenoid valve is open.<br />The drum is being filled. The “FILL” light is glowing. <br />Fig3<br />Drum filling is complete and the output of LEVEL SENSOR is true.<br />SOLENOID VALVE is closed.<br />FULL light is glowing and the motor starts.<br />Fig4<br />The drum is moving as the motor is ON and the FULL light is off.<br />Counter is incremented by one and is shown in the output numeric display. <br />I: 1/0 Power supply onvia push button.O: 2/0 Motor (by relay)<br />I: 1/1 Power supply off via push button.O: 2/1 Valve (by relay)<br />I: 1/2 Reset counter via push button.O: 2/2 Run Light<br />I: 1/3 Prox sensor O: 2/3 Fill Light<br />I: 1/4 Level sensorO: 2/2 Full Light<br />I: 1/5 Control A<br />I: 1/6 Control B<br />I: 1/7 Control C<br />LAD2<br />SBR3<br />SBR4<br />0 START 1 STOP 2 RESET 3 PROX SNC4 LVL SNC5 CNTL A6 CNTL B7 CNTL C<br />+24vCOMSMPSMCBSUPPLY240VISOLATION TRANSFORMER<br /> <br />0 1 2 3 4 5 6 7 <br />INPUTsRELAY <br /> PLC micrologix 1100A <br />0MOTOR 1 VALVE 2 RUN 3 FILL 4 FULL <br />OUTPUTs<br /> <br />0 1 2 3 4<br />This is a very essential system in large scale automatic filling stations and production houses. The output of the system is easily configurable using the regulator, and if the user wish to have more outputs then the ladder logic must be modified or may require to press the start button more than time to have outputs on a multiple of the preset values or even the counter value could be reset to obtain any arbitrary output.<br />This system is upgradeable too. If we attach sensors to the storage tank, then we will get the amount of fluid stored in the tank and the amount remained at the end of the process. All we need is to modify ladder logic and make change at the input-output sections.<br />So the system is highly configurable and suitable for industrial needs.<br />=======================================================<br /> Please Visit: www.karaoke-cosmos.blogspot.com<br />=======================================================<br />

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