e-ISSN: 2582-5208

International Research Journal of Modernization in Engineering Technology and Science

Volume:02/Issue:04/April- 2020 www.irjmets.com

DESIGNING A SCADA SYSTEM FOR A PRODUCTION BASED PLANT

Godavarthi Amar Tej*1, Akula K R Koteswara Rao*2, Kesanupalli Architha Swetha*3, Kodati
Bala Sai Sravanthi*4, Lakkisetty Meenakshi*5, Palla Venkata Sai Pravallika*6
*1
Asst.professor, Dept. of Electronics and Communication Engineering, Vasireddy Venkatadri
Institute of Technology, Andhra Pradesh, India.
*2
Engineer in Technical Service, Design Tech Systems Ltd, Hyderabad, Andhra Pradesh, India.
*3,4,5,6
Student, Dept. of Electronics and Communication Engineering, Vasireddy Venkatadri Institute
of Technology, Andhra Pradesh, India.

ABSTRACT
In any manufacturing industry monitoring and control of industrial parameters is very necessary since there are
many stages. Each stage requires many pre-processing activities that require different conditions. To monitor
and control all the stages that are required for production we are designing a distributed control system where
we can view each and every stage going in the work floor (i.e., flow of process and parameters like temperature,
flow and level measurements etc.). Design includes TIA portal and WINCC software. Control is observed on
HMI screen (touch panel) in animated form.
KEYWORDS: Arduino Uno, Supervisory Control And Data Acquisition (SCADA), Total Integrated
Automation (TIA), Human-Machine Interface Screen (HMI Screen).

I. INTRODUCTION
Production based plant consists of several processing steps based on the product it is manufacturing. But the pre
processing steps are common for any production plant irrespective of the product. The pre processing steps
involves cleaning section, heating section and cooling section.
Earlier, the parameters of the pre processing steps are monitored and controlled by the human being with his
presence at the plant. This requires more human power and it is very difficult for human to go to the uncertain
places in the plant. So to avoid all this automation has come into existence. Automation is the utilization of
different control techniques for operating equipment’s such as operations in factories, aircraft and other
applications with reduced human power and more accuracy.
This process is controlled with arduino Uno using arduino cc software. PLC is programmed using TIA software
and ladder logic is used. SCADA, a graphical user interface helps to control & monitor the entire process from a
control room.

II. METHODOLOGY
Method and analysis which is performed in your research work should be written in this section. A simple
strategy to follow is to use keywords from your title in first few sentences.

Design Process

Input
Input Cleaning Heating Cooling
Section Section Section Section

Fig-1: Block Diagram

www.irjmets.com @International Research Journal of Modernization in Engineering, Technology and Science

[8]
 e-ISSN: 2582-5208
International Research Journal of Modernization in Engineering Technology and Science
Volume:02/Issue:04/April- 2020 www.irjmets.com
This system can be seen in flow chart as follows:

III. MODELING AND ANALYSIS

For the efficient working of the prototype the design and was first implemented in NX software. In the NX
software components are chosen and assemblies are built with these components. We have used one main
assembly and four sub assemblies namely input section, cleaning section, heating and cooling section and
packing section. These sub assemblies are needed to avoid confusion and also for the reason that any
modifications in the sub assembly are reflected in main assembly. After assembling the components motion

www.irjmets.com @International Research Journal of Modernization in Engineering, Technology and Science

[9]
 e-ISSN: 2582-5208
International Research Journal of Modernization in Engineering Technology and Science
Volume:02/Issue:04/April- 2020 www.irjmets.com
simulation is done. This step is necessary to ensure that all the desired specifications are reached and the
prototype is working as required

Fig-2: Proposed System

Arduino is used as controller for servos and ultrasonic sensor. While PLC is used as controller for SCADA. An
ultrasonic sensor is used for continuous level measurement of the input section. If the level is less than 30% then
servo value will open letting seeds to cleaning section. Simultaneously when the value is opened grabber in the
cleaning section is kicked off for purification of seeds from dust. If the level of tank in input section reaches
80% then the servo valve will close.
After a five second as soon as the input servo valve is closed grabber of the cleaning section is ceased. Then
grabber will take a tilt of 120 degrees with the help of the servo motor connected to it. In the mean while pure
seeds are transferred to collecting tank. Then seeds are transferred to heating and cooling section via a screw
conveyor. Heating section consists of a vessel whose bottom part consists of flat heating element and a
thermostat is mounted above the heating section which set to a brim of 80 degrees. This is very important to
maintain particular temperature in the heating section. Heating section also consists of a stirrer for uniform
distribution of heat. A fins surface is made under heating section with a blower for cooling of seeds. As soon the
conveyor is kicked off stirrer and blower of heating and cooling section is on. Seeds will be in this section for
about one minute and via another screw conveyor they are sent to packing section i.e. the cooled seeds are
stored and sent for further processing.

Screw conveyor Description

It consists of a tube containing either a spiral blade coiled around a shaft, driven at one end and held at the other
or a “shaft less spiral”, driven at one end and free at the other. With the help of the servo motors controlled by
Arduino Uno, rotating helical screw blade within the tube moves the granular materials from one end to other
end.

www.irjmets.com @International Research Journal of Modernization in Engineering, Technology and Science

[10]
 e-ISSN: 2582-5208
International Research Journal of Modernization in Engineering Technology and Science
Volume:02/Issue:04/April- 2020 www.irjmets.com

Fig-3: Screw Conveyor

IV. RESULTS AND DISCUSSION

Result:

Fig-4: SCADA Screen

After signing in the screen it takes us to the SCADA view of the plant.

www.irjmets.com @International Research Journal of Modernization in Engineering, Technology and Science

[11]
 e-ISSN: 2582-5208
International Research Journal of Modernization in Engineering Technology and Science
Volume:02/Issue:04/April- 2020 www.irjmets.com

Fig-5: SCADA Main Screen

Future Scope:
 This design can be connected to the web server which will be used for starting of process from any
section irrespective of input section level.

 The processed seeds can be sent for oil production or can be used for any medicinal purpose and also in
culinary process.

V. CONCLUSION
 This we can deploy a SCADA system for pre processing of production based plant.

 This pre processing is necessary to reduce moisture content in the seeds and also to increase the yield of
the production.

 Previously there was a human involved in pre processing but this process is fully automated with no
human intervention and also the whole process results in the customized output of seeds which can be
directly deployed for further production.
 With this we can also have an estimate of quantity of raw inputs and the processed seeds quantity.

VI. REFERENCES
[1] https://new.siemens.com/Automation
[2] https://mtabindia.com/mechatronics
[3] https://designtechsystems.com
[4] https://www.techopedia.com/definition/32099/automation
[5] https://en.wikipedia.org/wiki/Screw_conveyor
[6] https://www.automationworld.com/home/news/13297758/siemens-launches-software-engineering-framework
[7] https://en.wikipedia.org/wiki/Siemens_NX
[8] https://www.researchgate.net/publication/3270341_Design_and_Implementation_of_PLC-
Based_Monitoring_Control_System_for_Induction_Motor
[9] https://en.wikipedia.org/wiki/Arduino_IDE
[10] https://realpars.com/scada/
[11] https://en.wikipedia.org/wiki/Programmable_logic_controller

www.irjmets.com @International Research Journal of Modernization in Engineering, Technology and Science

[12]