Sie sind auf Seite 1von 10

Automation of Batch process Using Programmable Logic Controller (PLC)

Advisor:

Engr. Yasir Anwar

Lecturer UCE&T, Bahauddin Zakriya university Multan

Final year project, session 2005-2009

Muhammad Ishtiaq

2005-CPE-10

Sidra Naseer

2005-CPE-11

Asad Abbas

2005-CPE-03

Shahbaz Hussain Baloch

2005-CPE-21

2005-CPE-03 Shahbaz Hussain Baloch 2005-CPE-21 Department of Computer Engineering University College of

Department of Computer Engineering University College of Engineering & Technology Bahauddin Zakriya University Multan

Department of Computer Engineering

The undersigned hereby certify that students have read and award a pass in Department of Computer

Engineering, University College of Engineering & Technology, Bahauddin Zakriya University for the

project entitled

“Automation of Batch process Using Programmable Logic Controller (PLC)”

In partial fulfillment of the requirement for the degree of B.Sc. Computer Engineering.

------------------------------------------

Engr. Yasir Anwar

(Lecturer)

Department of Computer Engineering

UCE&T BZU, Multan

-------------------------------------------

External Examiner

DedicationDedicationDedicationDedication

To

Our beloved parents

Whose efforts, prayers

&

Wishes have been an Inspiration

ACKNOWLEDGMENTACKNOWLEDGMENTACKNOWLEDGMENTACKNOWLEDGMENT

we are grateful to ALLAH ALMIGHTY the most merciful, the most beneficent, who is entire source of

knowledge and wisdom, who bestowed us health, abilities and guidance to complete the project in a

successful manner.

we would like to acknowledge our project advisor Engr. yasir anwar for his support and efforts. He was

always there to guide us whenever we felt stuck off and his encouragement always worked as moral

booster for us.

We are thankful to Engr.Ahsan Khalil

for his encouragement and guidance.

AbstractAbstractAbstractAbstract

This project focused on the understanding and experiencing

“programmable Logic controller”

programming “Ladder

Logic”. programmable Logic controller is widely used in industries for

controlling different parameters. we implement the automation of batch process by controlling

different instruments and devices with help of

programmable Logic controller.

Batch process is 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. Batch process is common in bakeries and

in the manufacture of sports shoes, pharmaceutical ingredients , food manufacturing, inks, paint

and adhesives. The problems is batch process are the majority of industry is using manual that’s

efficiency is dependent on operator. These are time consuming, have low production and high

cost. For these problems we have to automate the process by using PLC. Programmable Logic

Controller (PLC) is a digital device, which uses programmable memory that coordinates several

input and output devices to control different processes. For automation of batch process using

PLC we have to control three phase induction motors, water pump through press control,

thermocouple, heating device, and pneumatic valves. For automating the batch process in candy

preparation industry.

TableTableTableTable ofofofof contentscontentscontentscontents

1

AUTOMATION…………………………………………………

1.1

BASIC COMPONENTS OF AUTOMATION………………………

1.2

TYPES OF AUTOMATION………………………………………….

1.3

PROBLEM STATEMENT (BATCH PROCESS)…………………….

1.4

INSTRUMENTS OVERVIEW IN AUTOMATION …………

2

BATCH PROCESS………………………………………………

 

2.1

INTRODUCTION TO BATCH P ROCESS…………………………

2.2

BATCH PROCESS AUTOMATION………………………………

2.3

REASONS TO AUTOMATE BATCH PROCESS………………….

2.4

STANDARDS FOR BATCH CONTROL…………………………

2.5

CONSIDERATION OF S88 STANDARD …………………………

2.6

AUTOMATION OF BATCH PROCESS WITH PLC………………

2.7

REQUIREMENTS FOR AUTOMATING BATCH PROCESS

 

CONTROL WITH PLC………………………………………………

3

PROGRAMMABLE LOGIC CONTROLLER……………….

 

3.1

INTRODUCTION …………………………………………………

3.2

THE ROLE OF PLC………………………………………………….

3.3

PLC BASICS………………………………………………………….

3.4

CONSTRUCTION OF A PLC…………………………………………

3.5

PLC ATCHITECTURE………………………………………………

3.6

CHARACTERISTIC FUNCTIONS OF A PLC……………………

3.7

TYPES OF PLC…………………………………………………………

3.8

DESCRIPTION OF THE PLC SOFTWARE………………………….

3.9

PLC PROGRAMMING………………………………………………

3.10

SPECIFICATION OF DELTA DVP-SS…………………………………

4 WPL SOFTWARE………………………………………………

4.1

SYSTEM REQUIREMENT……………………………………………

4.2

INSTALLATION AND PROGRAM EXECUTION………………….

4.3

SETUP………………………………………………………………….

4.4

LADDER DIAGRAM MODE…………………………………………

4.5

INSTRUCTION MODE………………………………………………

4.6

EDITING COMMENTS………………………………………………

4.7

COMMUNICATION…………………………………………………

4.8

SFC EDITING ENVIRONMENT………………………………………

4.9

SIMULATOR…………………………………………………………

5 INSTRUMENTS & DEVICES………………………………….

5.1

PRESS CONTROL……………………………………………………

5.2

THREE PHASE INDUCTION MOTOR……………………………….

5.3

FREQUENCY INVERTER………………………………………

5.4

PNEUMATIC VALVE…………………………………………………

5.5

THERMOCOUPLE…………………………………………………….

5.6

TEMPERURE CONTROLLER………………………………………

6 DESIGN & IMPLIMENTATION……………………………

6.1

CONTROLLER PHILOSOPHY…………………………………………….

6.2

MAIN FUNCTIONS T AUTOMATE……………………………………….

6.3

PROJECT DIAGRAMS.…………………………………………………….

6.4

IMPLEMENTATION OF FUNCTIONS……………………………………

ListListListList ofofofof FiguresFiguresFiguresFigures

Figure 1.1:

components of automation……………………………………

Figure 2.1:

classic S95 control hierarchy………………………………….

Figure 2.2:

S-95 Levels with Applications……………………………….

Figure 2.3:

Information Exchange Between Levels 3 & 4……………….

Figure 2.4

Business planning & Logistics……………………………….

Figure 2.5:

The Concept of Control………………………………………

Figure 2.6:

Separate Recipe and Equipment Control……………………

Figure 2.7:

Everything Breaks Into Pieces………………………………

Figure 2.8:

A Recipe Explosion…………………………………………

Figure 2.9:

The Procedural Control Model……………………………….

Figure 2.10:

A candy Recipe Procedure…………………………………

Figure 2.11:

The Make Mix Unit Procedure……………………………….

Figure3.1:

PLC conceptual application diagram…………………………

Figure3.2:

Model of PLC………………………………………………

Figure 3.3:

Modular PLC I an automated system………………………

Figure 3.4:

Memory and processors in CPU of PLC…………………….

Figure 3.5:

The power supply in a plc system…………………………

Figure 3.6:

Manually switch controlling of lamp……………………….

Figure 3.7:

Product profile and outline………………………………….

Figure 3.8:

Wirring of Power Terminal…………………………………

Figure 3.9:

input/output wiring………………………………………….

Figure 4.1

WPL soft……………………………………………………

Figure 4.2

opening Window……………………………………………

Figure 4.3:

Modes of Programming……………………………………

Figure 4.4:

Example Ladder Diagram…………………………………….

Figure 4.5:

Instruction Mode Window……………………………………

Figure 4.6:

Edit device Comment Window………………………………

Figure 4.7:

auto-detect the PLC communication…………………………

Figure 4.8:

sequential function chart editor………………………………

Figure 4.9:

SFC Environment…………………………………………

Figure 4.10:

SFC Editing Instruction………………………………………

Figure 4.11:

Ladder Monitoring……………………………………………

Figure 4.12:

Debug Mode………………………………………………….

Figure 5.1:

press control………………………………………………….

Figure 5.2:

Component of press control………………………………….

Figure 5.3:

Installation of pres control …………………………………

Figure 5.4:

Electrical wiring of press control…………………………….

Figure 5.5:

Closed squirrel-cage three-phase motor……………………

Figure 5.6:

Rotor voltage UR is a proportional function of slip s……….

Figure 5.7:

Operating characteristics of an induction motor…………….

Figure 5.8:

Circuit Diagram of Inverter………………………………….

Figure 5.9:

circuit configuration ………………………………………

Figure 5.10:

Pneumatic Valve…………………………………………….

Figure 5.11:

Thermocouple ………………………………………………

Figure 5.12:

Temperature Transmitter ……………………………………

Figure 6.1:

Recipe Chart………………………………………………

Figure 6.2:

Block Diagrame project…………………………………….

Figure 6.3:

Model Diagrame……………………………………………

Figure 6.4:

process Flow Chart…………………………………………

ListListListList ofofofof TablesTablesTablesTables

Table 3.1:

Response time of PLC……………………………………

Table 3.2

Plc specifications………………………………………

Table 4.1:

Editing the Ladder Diagram………………………………

Table 4.2:

Shortcuts For Editing……………………………………

Table 4.3:

SFC Editing……………………………………………….

Table 5.1:

Typical synchronous speeds in a 50 Hz circuit…………

Table 5.2:

Specification of inverter………………………………….