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The main purpose of the project is to maintain fluid in a desire level to any
control system. PLC is used in this project as an Automation tool to reduce
manual operation and get better accuracy.
Introduction:
In the past, humans were the main methods for controlling a system. More
recently electricity has been used for control and early electrical control was
based on relays. These relays allow power to be switched on and off without a
mechanical switch. It is common to use relays to make simple logical control
decisions. The development of low cost computer has brought the most recent
revolution. The Programmable Logic Controller (PLC) is widely used in different
plants like power generation, boiler, level control, chemical plants, textiles mills,
paper plant, water treatment plant and food processing plant. Most of the
present science and technology of the control system is based on
microcontroller and PLC. This project work is done to present methods for
designing controls software using Programmable Logic Controllers (PLC).
The advance of the PLC began in the 1970 and has become the most common
choice for manufacturing controls. PLC has been gaining popularity on the
factory floor and will probably remain predominant for some time to come. Most
of this is because of the advantages they offer.
The PLC is not only are capable of performing the same tasks as hard-wired
control, but are also capable of many more complex applications. In addition,
the PLC program and electronic communication lines replace much of the
interconnecting wires required by hard-wired control. Therefore, hard wiring,
though still required to connect field devices, is less intensive. This also makes
correcting errors and modifying the application easier. Some additional
advantages of PLC are as follows:
• Reliable components make these likely to operate for years before failure.
Fundamental of PLC
A PLC works by continually scanning a program. We can think of this scan cycle
as consisting of 3 important steps. There are typically more than 3 but we can
focus on the important parts and not worry about the others. Typically the others
are checking the system and updating the current internal counter and timer
values.
Step 1
Check input status: First the PLC takes a look at each input to determine if it is
on or off other words, is the sensor connected to the first input on? How about
the 2nd input? About the third. It records this data into its memory to be used
during the next step.
Step 2
Execute program: Next the PLC executes program one instruction at a time.
May be program said that if the first input was on then it should turn on the first
output. Since it all knows which inputs are On & Off from the previous step will
be able to decide whether the output should be turned on based on the state of
the first input. It will store the execution result or use later during the next step.
Step 3
Update output status: Finally the PLC updates the status of the outputs. It
updates the outputs based on which inputs were on during the first step and the
results of executing program during the second step. Based on step 2 it would
now turn on the first output because the first input was on and program said to
turn on the first output when this condition is true. After the third step the PLC
goes back to step 1 and repeats the steps continuously. One scan time is
defined as the time it takes to execute the 3 steps listed above.
Easy to program
The interfacing for inputs and outputs is inside the controller.
Does not suffer from fatigue problem
Can be checked without field device
Can perform complex logic operation
Can interface with computer
Faster system response
Monitoring facilities available
High reliability
Easy to maintenance
PLC is actually an industrial micro controller system where hardware and software specifically
adapted to industrial environment. Special attention needs to be given to input and output.
Because in these blocks we find protection needed in isolating a CPU blocks from damaging
influences that industrial environment can bring to a CPU via input lines. Program unit is usually
a computer used for writing a program
The control program can be entered into the PLC by using a simple form of high
level language like ladder diagram, instruction code etc. the input device such
as switch, push button, sensor and output device such as motor, relays, valves,
lamps etc. are connected to PLC. The operator then enters a sequence of
instructions into the memory of the PLC. The controller then monitors the inputs
and outputs according to these programs and carries out the control rules for
which it has been programmed.
Manual control- when the operator to operate the process to a desired condition,
then it carries out the corrective action is said to be manual control. The operator
adjusts the output to operate the plant. During start-up, this mode is normally
used.
Automatic control
When the instruments carry out the corrective action, then it is automatic
control.
Increase production
Improve quality
Greater production uniformity
Saving in raw materials
Saving in manpower
PLC not only are capable of performing the same tasks as hard-wired control,
but are also capable of many more complex applications. In addition, the PLC
program and electronic communication lines replace much of the
interconnecting wires required by hard-wired control. Therefore, hard wiring,
though still required to connect field devices, is less intensive. This also makes
correcting errors and modifying the application easier. Some of the additional
advantages of PLC are as follows:
• High reliability
• Computing capabilities
• Reduced costs
• Expandability
The CPU evaluates the status of inputs, outputs, and other variables as it
executes a stored program. The CPU then sends signals to update the status
of outputs. Output modules convert control signals from the CPU into digital or
analog values that can be used to control various output devices. The
programming device is used to enter or change the PLC’s program or to monitor
or change stored values. Once entered, the program and associated variables
are stored in the CPU. In addition to these basic elements, a PLC system may
also incorporate an operator interface device to simplify monitoring of the
machine or process.
The central processing unit (CPU) is the part of a programmable controller that
retrieves, decodes, stores, and processes information. It also executes the
control program stored in the PLC’s memory. In essence, the CPU is the
“brains” of a programmable controller. It functions much the same way the CPU
of a regular computer does, except that it uses special instructions and coding
to perform its functions.
• The processor
The processor is the section of the CPU that codes, decodes, and computes
data. The memory system is the section of the CPU that stores both the control
program and data from the equipment connected to the PLC. The power
supply is the section that provides the PLC with the voltage and current it needs
to operate.
The control program is a software program in the PLC’s memory. It’s what puts
the control in a programmable controller. The user or the system designer is
usually the one who develops the control program. The control program is made
up of things called instructions. Instructions are, in essence, little computer
codes that make the inputs and outputs do what you want in order to get the
result you need. There are all different kinds of instructions and they can make
a PLC do just about anything (add and subtract data, time and count events,
compare information, etc.). All you have to do is program the instructions in the
proper order and make sure that they are telling the right devices what to do
and voila…you have a PLC-controlled system. And remember, changing the
system is a snap. If you want the system to act differently, just change the
instructions in the control program. Different PLC offer different kinds of
instructions. That’s part of what makes each type of PLC unique. However, all
PLC use two basic types of instructions:
• Contacts
• Coils
Contacts- Contacts are instructions that refer to the input conditions to the
control program that is, to the information supplied by the input field devices.
Each contact in the control program monitors a certain field device. The contact
waits for the input to do something in particular (e.g., turn on, turn off, etc.—this
all depends on what type of contact it is). Then, the contact tells the PLC’s
control program, “The input device just did what it’s supposed to do. You’d
better check to see if this is supposed to affect any of the output
devices.”Coils- Coils are instructions that refer to the outputs of the control
program that is, to what each particular output device is supposed to do in the
system. Like a contact, each coil also monitors a certain field device. However,
unlike a contact, which monitors the field device and then tells the PLC what to
do, a coil monitors the PLC control program and then tells the field device what
to do. It tells the output device, “Hey, the PLC just told me that the switch turned
on. That means that you’re supposed to turn on now. So let’s go!”
Example- Let’s talk again about that soaped-up switching circuit, in which a wall
switch and an overhead light are connected to a PLC. Let’s say that Turning on
the switch is supposed to turn on the light. In this situation, the PLC’s control
program would contain a contact that examines the input device the wall switch
for an on condition and a coil that references the light. When the switch turns
on, the contact will energize, meaning that it will tell the PLC that the condition
it’s been looking for has happened. The PLC will relay this information to the
coil instruction by energizing it. This will let the coil know that it needs to tell its
referenced output the light to turn on.
In PLC talk, this three-step process of monitoring the inputs, executing the PLC
control program, and changing the status of the outputs accordingly is called
the scan.
Chapter: 2
Project implementation
Project Diagram
I3 → System Switch
Output:
Q1 → Pump (Motor)
Q4 → System Relay
Working Principles
When the system switch I3 is ‘ON’ the Over all systems ‘ON’.
When the fluid level in overhead tank decreases and the sensor I5 indicate the
minimum level. The Pump will go in START mode. The fluid will go in to the
overhead tank and both solenoid Q2 and Q3 (for middle tank and reserve tank)
will go in OFF mode.
When the fluid level in overhead tank increases and the sensor I2 indicate the
maximum level. The Pump will go in OFF mode and both solenoid Q2 and Q3
(for middle tank and reserve tank) will go in ON mode. The fluid will flow down
in to the Middle tank.
When the fluid level of the lower tank rises up and the sensor I4 indicate the
maximum level. Both solenoids Q2 and Q3 will go in OFF mode and the pump
will go in START mode. The fluid will go in to the overhead tank again
The cycle will be continued
Solenoid:
Sensor:
There are two weight sensor used in the overhead tank and the lower tank. This
two sensor gives the input signals (I1, I2, I4 , I5) as stated above.
Mounting of switch:
With these contacts the regulator closes when up opens when down.
With these contacts the regulator closes when down opens when up.
Control Penal
Logic diagram (program)
In this photo you can notice a large number of electrical wires, time relays,
timers and other elements of automation typical for that period. Pictured control
panel is not one of the more “complicated” ones, so you can imagine what
complex ones looked like. Most frequently mentioned disadvantages of a
classic control panel are:
3. Diagnostic functions of a PLC controller allow for fast and easy error
detection.
First, you need to select an instrument or a system that you wish to control.
Automated system can be a machine or a process and can also be called an
process control system. Function of an process control system is constantly
watched by input devices (sensors) that give signals to a PLC controller. In
response to this, PLC controller sends a signal to external output devices
(operative instruments) that actually control how system functions in an
assigned manner (for simplification it is recommended that you draw a block
diagram of operations’ flow).
Secondly, you need to specify all input and output instruments that will be
connected to a PLC controller. Input devices are various switches, sensors and
such. Output devices can be solenoids, electromagnetic valves, motors, relays,
magnetic starters as well as instruments for sound and light signalisation.
Following an identification of all input and output instruments, corresponding
designations are assigned to input and output lines of a PLC controller.
Allotment of these designations is in fact an allocation of inputs and outputs on
a PLC controller which correspond to inputs and outputs of a system being
designed.
Finally, program is entered into the PLC controller memory. When finished with
programming, check up is done for any existing errors in a program code (using
functions for diagnostics) and, if possible, an entire operation is simulated.
Before this system is started, you need to check once again whether all input
and output instruments are connected to correct inputs or outputs. By bringing
supply in, system starts working.
Chapter: 4
Competence
Program support
Programming only related examples make up the first group of examples. They
are given as separate small programs that can later be incorporated into larger
ones. Second group consists of examples, which can be applied to some real
problems.
Self-maintenance
Program allows input to remain at ON status even when the condition that
brought it to that status stops. Example in picture below illustrates how use of a
key connected to the input IR000.00 changes IR010.01 output status to ON. By
letting the key go, output IR010.01 is not reset. This is because IR010.01 output
keeps itself at status ON through OR circuit (having IR000.00), and it stays in
this status until key at input IR000.01 is pressed. Input IR000.01 is in I
connection with the output pin IR010.01 that cancels out a condition, and resets
an IR010.01 bit. Example of self-maintenance is quite frequent in specific
applications. If a user was connected to IR010.01 output, START and STOP
functions could be realized from two keys (without the use of switches).
Specifically, input IR000.00 would be a START key, and IR000.01 would be a
STOP key.
Making large time intervalsIf it’s necessary to make a bigger time interval of
999.9 seconds (9999×0.1s) two linked timers, or a timer and a counter can be
used as in this example. Counter is set to count to 2000, and timer is set to 5
seconds, which gives a time interval of 10.000 seconds or 2.77 hours. By
executing a condition at IR000.00 input, timer begins to count. When it reaches
the limit, it sets a flag TIM001 that interrupts the link and simultaneously resets
a timer. Once 5 seconds have run out, flag TIM001 changes its status to ON
and executes a condition at the counter input CNT002. When a counter
numbers 2000 such changes in timer flag status, TIM001 sets its flag CNT002
which in turn executes a condition for IR010.00 to change status to ON. Time
that has elapsed from the change of IR000.00 input status to ON and a change
of IR010.00 input status to ON come to 10.000 seconds.
Example shows how to make output (IR010.00) delay as opposed to? (In
relation to? unclear meaning) input (IR000.00). By executing a condition at
IR000.00 input, timer TIM000 begins counting a set value 10 in steps of 0.1
seconds each. After one second has elapsed, it set its flag TIM000 that is a
condition in changing output status IR010.00 to ON. Thus we accomplish a
delay of one second between ON status of IR000.00 input and ON status
IR010.00 input. By changing IR010.00 output status to ON, half of the condition
for activation of the second timer is executed. Second half of the timer is
executed when IR000.00 input changes status to OFF (normally closed
contact). Timer TIM001 sets its flag TIM001 after one second, and interrupts a
condition for keeping an output in ON status.
Counter over 9999
If you need to count over 9999 (maximum value for a counter), you can use two
connected timers. First counter counts up to certain value, and the other one
counts flag status changes of the first counter. Thus you get the possibility of
counting up to a value that is a result of set values of the first and second
counter. In an example at the bottom, first counter counts up to 1000, and
second up to 20 which allows you to count to 20000. By executing a condition
at IR000.00 input (line whose changes are followed is brought to it), first counter
decreases its value by one. This is repeated until counter arrives at zero when
it sets its flag CNT001 and simultaneously resets itself (is made ready for a new
cycle of counting from 1000 to 0). Each setting of CNT001 influences the other
counter which sets its flag after twenty settings of the first counter’s flag. By
setting CNT002 flag of the second counter, a condition is executed for an
IR010.00 output to be activated and to stay in that status through self-
maintenance.
Same effect can be achieved with a modified program below. First change is
that there is a “switch” for the whole program, and this is IR000.00 input
(program can accomplish its function only while this switch is active). Second
change is that the line whose status is followed is brought to IR000.01 input.
The rest is the same as in the previous version of the program. Counter CNT002
counts status changes of the CNT001 counter flag. When it numbers them, it
changes the status of its flag CNT002 that executes the condition for status
change of IR010.00 output. This changes IR010.00 output status after 20000
changes of input IR000.01.
It also can use in arithmetic functions of different process and modern industries
like pharmaceuticals, Fertilizer, Power station, Cement factory, packaging and
so on.
It has been a great pleasure to work on practice & progress of PLC based fluid
level control system. It provides information about many topics relevant to
controlling system or equipment automation. We have more learned about the
fuel & water level control system. It can run automatically by the help of PLC.
The great advantage of PLC based fuel & water level control system is with
maximum accuracy. Also the system has higher reliability, small space
requirements reduced cost and able to work as friendly with environment.
Further Recommendation
Firstly, we can make this project in less cost and due to its high expenses it is
not a good idea in mass production. Secondly, it required less space then
Programmable Logic Controller. Thirdly, PLC cannot handle complex situation.
That’s why, now a days- Microcontroller is used thoroughly in process control,
control of machinery, Factory assembly line, Upgrade automotive Vehicle
also…