Beruflich Dokumente
Kultur Dokumente
Submitted by: Tejinderbir Singh B.Tech 4th year, Electrical Engineering Enrol No.: 10115108
Contents
Topic
1. Introduction 2. Programmable Logic Controller 2.1 Introduction to PLC 2.2 PLC Hardware 2.3 PLC Input/Outputs 2.4 Advantages of PLC over Relay Controls 2.5 PLC in Automation 2.6 PLC Communication 2.7 Components of the PLC 3. Programming the PLC 4. Binary Logic Control 4.1 Logic Control and Sequencing 4.2 Logic Control Elements 4.3 Logic Ladder Diagram 5. Automation of Fuel delivery system
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Conclusion References
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Abstract
The report first introduces about Programmable Logic Controller (PLC). It describes about PLC components, hardware, its inputs/outputs . It then discusses about advantages of PLC over relay controls and how by programming the PLC using Ladder Logic and communicating PLC with a computer, PLC can be used for automation of various physical processes. The later part of report discusses about Binary Logic used in Ladder Programming and Binary Logic Control. Last part of report refers to the project Automation of Fuel Delivery System I did during internship and describes the program used for Automation of Fuel Delivery System using Ladder Logic.
Chapter-1
Introduction
Industrial Automation is the use of programmable and logic devices to complete manufacturing and controlling tasks. In this age of computers, industrial automation is becoming increasingly important as computerized systems are capable of handling repetitive tasks quickly and efficiently. In addition, the company can save money because it does not need to pay for expensive benefits for this specialized machinery. Automation of many different process, such as controlling machines or factory assembly lines, is done through the use of small computers called a Programmable Logic Controller (PLC). In our project we are automating the Fuel delivery system of aircrafts. The program for the PLC is developed using Ladder Logic.
Chapter-2
Communication abilities began to appear in approximately 1973. The first such system was Modicons Modbus. The PLC could now communicate with other devices and they can be far away from the actual machine they were controlling. They could also now be used to send and receive varying voltages to allow them to allow them to enter the analog world. The 80s saw an attempt to standardize communications with General Motors Manufacturing Automation Protocol(MAP). I t was also a time for reducing the size of the PLC and making them software programmable through symbolic programming on personal computers instead of dedicated programming terminals or handheld programmers. Today the worlds smallest is about the size of a single control relay. The 90s have seen a gradual reduction in the introduction of new protocols, and the modernization of the physical layers of some of the more popular protocols that survived the 1980s. The latest standard (I EC 1131-3) has tried to merge PLC programming languages under one international standard. We now have PLCs that are programmable in function block diagrams, instruction lists, C and structured text all at the same time. PCs are also being used to replace PLCs in some applications. The original company who commissioned the MODI CON 084 has actually switched to a PC based control system. One of the very first 084 models built is now display at Modicons headquarters in North Andover, Massachusetts . Most of this is because of the advantages they offer are
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I mprove product quality through enhanced monitoring and data acquisition capabilities and tighter control. I mprove scalability (ease of expansion). Standardize programming. Cost effective for controlling complex systems . Flexible and can be reapplied to control other systems quickly and easily. Computation abilities allow more sophisticated control. Trouble shooting aids make programming easier and reduce downtime . Reliable components make these likely to operate for years before failure.
Consider the example of a light bulb. I f it can only be turned on or off, it is logical control. I f the light can be dimmed to different levels, it is continuous. Continuous values seem more intuitive, but logical values are preferred because they allow more certainty, and simplify control. As a result most controls applications (and PLCs) use logical inputs for most applications. Hence, we will discuss logical I /O. I nputs come from sensors that translate physical phenomena into electrical signals. Typical examples of sensors are listed below. 1. Proximity Switches- use inductance, capacitance or light to detect an object logically. 2. Switches mechanical mechanisms will open or close electrical contacts for a logical signal. 3. Potentiometer measures angular positions continuously, using resistance. 4. LVDT (linear variable differential transformer) measures linear displacement continuously using magnetic coupling. Outputs to actuators allow a PLC to cause something to happen in a process. A short list of major actuators is given below. 1. Solenoid Valves logical outputs that can switch a hydraulic or pneumatic flow. 2. Lights logical outputs that can often be powered directly from PLC output boards. 3. Motor Starters motors often draw a large amount of current when started, so they require motor starters, which are basically large relays. 4. Servo Motor a continuous output from the PLC can command a variable speed or position.
At first, any production engine is electronically controlled, requiring each control, for example, 12 machine requires 12 controller. Now by using the model of the PLC can control any of the 12 machines. Each machine is controlled by its own respective programs.
2. Implementing Change and error correction
By using the type of relay that is connected to the panel, program changes will take time to re-connect panels and equipment. While using the PLC, to make changes to the program, does not require a long time is by way of a change in software. And if the program error occurs, then the error can be directly detected by monitoring its existence directly. The change is very simple, just change its ladder diagram.
3. Low Price
PLC is simpler in shape, size, and other devices that support it, so the price can be reached. Current can be purchased the following PLC timers, counters, and analog inputs in a single CPU package. PLC easy to get, and now many in the market with different brands and types.
4. Contact number is much
PLC has a number of contacts for each coil are many available. For example, the panel that connects the relay has 5 contacts and all use while on the design changes needed 4 more contact means required the addition of a single relay again. By using PLC, typing required just to make contact again 4 pieces. Hundreds of contacts can be used
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The series of PLC programs can be tested first, tested, examined and modified at the office or laboratory, so the time efficiency can be achieved. To test the PLC program does not have to be installed first to the instrument to be executed, but can be seen directly in the PLC CPU or seen in the supporting software.
6. Visual Observation
Operation of the circuit can be seen during the PLC operated directly via the CRT screen. If there are errors or mistakes that other operations can be immediately known. Logic path will light up on the screen so that repairs can be done quickly through visual observation. Even some PLC can provide an error message if it occurs.
7. The Operating Speed
Operating speed of the PLC, exceeds the operating speed than relay at work, which in a few micro-seconds. So as to determine the speed of the output of the tools used.
8. Boolean or Ladder Method
PLC programs can be done with a ladder diagram by the technician or also use bolean or digital system for the programmers.
9. Reliability
Solid state equipment is generally more resistant than mechanical relays or timers. PLC is able to work in severe
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PLC is one piece of equipment with a delivery time. If the PLC arrives, then all relays, counters, and other components also arrived. If the relay panel design as much as 10 pieces, it would require 10 different supplier delivery time, so if you forgot to order one relay will result in delays in processing a panel.
11. Documentation
Print series PLC can be done real soon in part or whole without the need to look at a series of bl ueprints that are not necessarily up to date, and also do not need to check the wiring to the circuit path.
12. Security
PLC programs can not be changed by anyone and can be made password. While the regular relay panel allows for changes that are difficult to detect.
13. Facilitate Change by Reprogramming
PLC can be quickly re-programmed, it is possible to mix the production process, while the other is running production.
reducing the need for human intervention. I n the scope of industrialization, automation is a step beyond mechanization. Whereas mechanization provided human operators with machinery to assist them with physical requirements of work, automation greatly reduces the need for human sensory and mental requirements as well. Process and system can also be automated. Automation plays an increasingly important role in the global economy and in daily experience. Engineers strive to combine automated devices with mathematical and organizational tools to create complex system for a rapidly expanding range of applications. Specialized hardened computers, referred to as PLCs are frequently used to synchronize the flow of inputs to actuators and events. This leads to precisely controlled actions that permit a tight control of almost any industrial process. The programmable logic controller has made a significant contribution to factory automation. Earlier automation systems had to use thousands of individual relays and cam timers, but all of the relays and timers within a factory system can often be replaced with a single programmable logic controller. Today, programmable logic controllers deliver a wide range of functionality, including basic relay control motion control, process control, and complex networking, as well as being used in Distributed Control Systems
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Chapter-3
The low-level languages are generally limited to the types of logic and sequencing functions that can be defined in a ladder logic diagram. Although timers and counters have not been illustrated in the two preceding examples, some of the problems at the end of the chapter require the reader to make use of them. High-level computer-type languages are likely to become more common in the future to program the PLC. There are several of these languages that are beginning to be offered commercially, including [ SYBIL (GTE Sylvania), MCL mod el APC2 (Cincinnati Milacron), and Control Statements (Reliance Electric). Most of the available languages use an instruction set that is similar to the BASIC computer language for personal computers. There are additional statements available beyond the normal BASIC set to accomplish the control functions. The principal advantage offered by the high-level languages for programming the PLC is their capability to perform data processing and calculations on values other than binary. Ladder logic diagrams and lowlevel OPLC languages are usually quite limited in their ability to operate on signals that are other than ON/OFF types. The capability to perform data processing and computation permits the use of more complex control algorithms, communications with other computer-based systems display of data on a CRT console, and input of data by a human operator. Another advantage of the higher-level languages is the relative case with which a user can interpret a printout of a complicated control program. Explanatory comments can be inserted into the program to facilitate the interpretation.
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Chapter-4
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Fig 4.1 Logical AND gate: (a) Circuit illustrating the operation, (b) Its truth table
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Logic Gate OR
The logic gate OR outputs a value of 1 if either of the inputs have a value of 1, and 0 otherwise. In this case, Xl and X2 are arranged in a parallel circuit, so that if either of the switches is closed, the lamp Y will be on. The truth table for the OR gate is shown in Figure.
Fig 4.2 Logical OR gate: (a) Circuit illustrating the operation (b) Its truth table
Fig 4.3 Logical NOT gate: (a) Circuit illustrating the operation, (b) Its truth table
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Symbols for common logic and sequence components in a ladder logic diagram
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Chapter-5
Fuel Pump
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The pump starts as soon as start is pushed and remains in the operating mode unless stop key is pressed. The sensors sense the operation and give the indication whether pump is running(green) or not(red).
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Conclusion
The whole experience of working at HAL was great. This organization has a superb work culture, great minds and very high quality of work. I learned a lot of about Programmable Logic Controller and its use in making processes automatic . The work I could complete here was very satisfactory. I used the developed ladder program for fuel delivery system of Jet Turbo engine in HAL and got good results. The program worked as expected. I hope my work on PLC Programming and Automation of Fuel Delivery System helps HAL meet its goals.
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References
1.Kevin Collins : PLC Programming for industrial Automation 2. Neal Babcock : Beginner's Guide to PLC Programming 3. Wikipedia: http://en.wikipedia.org/wiki/Programmable_l ogic_controller 4. Wikibooks: http://en.wikibooks.org/wiki/Introductory_PL C_Programming
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