3.

PLC BASED SPECIAL PURPOSE LOADING SYSTEM

INTRODUCTION
In Nuclear Fuel Complex (NFC), the raw uranium material is processed and done in the form of Uranium dioxide pellets. These pellets are manually loaded into Zircaloy tubes, which are further processed and used as fuel rods in the Pressurized Heavy Water Reactors (PHWRs). The fuel for this nuclear reactors is in the form of 19 element or 37 element type Bundles. In the manufacture of nuclear fuel elements, the process of loading the fuel pellets into the finished Zircaloy tubes as been rendered very difficult because of very less clearance between the inside diameter of the tube and the pellet diameter. This is further aggravated by the permissible wider tolerance in the nominal dimensions and classification into different ranges. The difficulty leads to damage to the end-face of the tube through which the pellets are loaded. The damaged end face leads to poor quality of the end-cap of the fuel element. The end cap weld is the joint in the first level containment for the radioactive fuel material and has to conform to extreamly stringent quality standards. Hence to, avoid the damage to the tube end face and subsequent rejection of the fuel element, only high skilled employ are entrusted with job of loading pellets into the tubes, moreover it is time consuming factor. To overcome all this difficulties, we have implemented this project.

OVERCOMING THE DIFFICULTIES

The aim of the project PLC BASED SPECIAL PURPOSE LOADING SYSTEM is to load the Uranium dioxide pellets into Zircaloy tubes automatically using a PLC. Now it has become possible to mechanically load the stack of pellets- not just into one tube but into- all 19 tubes necessary to make a fuel bundle simultaneously with out causing damage to the fuel tube end-faces. In addition to just loading the pellets into tubes the system developed incorporates a suitable weigh system to measure the weight of the Zircaloy tubes before and after the pellets are loaded. The weight of the Zircaloy tubes is seen on the weigh system and the data is transferred to the computer through RS-232 serial port interface between the weigh system and computer.

PLC BASED SPECIAL PURPOSE LOADING SYSTEM

CLOSER VIEW OF PUSHING THE STACK OF PELLETS INTO ZIRCALOY TUBES The PLC BASED SPECIAL PURPOSE LOADING SYSTEM consists of following units: 1) FX2N Programmable Logic Controller 2) Solenoids 3) Relays 4) Switch Mode Power Supply 5) Proximity Sensors 6) Human Machine Interface 7) Pellet Tray 8) Rod Tray 9) Weigh System 10) Induction Motor

FX2N PLC

The FX2N series base units are are available with 16, 32, 48, 64, 80 or 128 input/output points.It is possible to choose between relay and transistor output type. Triac output types for 110 V AC for sink/source are also available. Over 30 types of special function and additional I/O modules are available to customise FX2N to your automation tasks. Advanced analogue design mean that in many cases the same block can be used for voltage current operation and, in the case of the FX2N-8AD, additional temperature operations as well. I/O range 16-256 Program memory 16k steps (with memory cassette). INSTRUCTION TIMES Basic instructions: 0.07 s / logical instruction. FEATURES 1) Exchangeable interface modules for direct mounting into a base unit 2) Standard programming unit interface 3) LEDs for indicating the input and output status 4) Detachable terminal blocks (except for 16 I/O base units) 5) Slot for memory cassettes for up to 16 k steps PLC program 6) Integrated real-time clock. 1. FLEXIBILITY CONFIGURATIONS FX2N series PLC can be extended up to 256 i/o in addition to the ability to add eight special function blocks. 2. HIGH SPEED OPERATION Basic instruction 0.08micro seconds/instruction Application instruction: 1.52 to several 100 microseconds/instructions. 3. RELIABILITY A plc that runs dont crash and the same cant be guaranteed with a pc. The plc doesnt crash because a plc hardware is robust and you dont have to remove a frame to exchange cards 4. With our pc and field bus based solution you can exchange the i/o modules at run time 5. The technical maintenance personnel is more familiar with the plc this counts as well for programming as hardware probes 6. Rugged and designed to withstand vibrations, temperature, humidity and noise 7. Have interfacing for inputs and outputs already inside the controller.

FX-2N PROGRAMMABLE LOGIC CONTROLLERS

SOLENOID
A solenoid valve is an electromechanical device used for controlling liquid or gas flow. The solenid valve is controlled by electrical current, which is run through a coil. When the coil is energized, a magnetic field is created, causing a plunger inside the coil to move. Depending on the design of the valve, the plunger will either open or close the valve. When the electrical current is removed from the coil, the valve will return to its deenergized state.

In direct-acting solenoid valves, the plunger directly opens and closes an orifice inside the valve. In pilot-operated valves (also called the servo-type), the plunger opens and closes a pilot orifice. The inletline pressure, which is led through the pilot orifice, opens and closes the valve seal.

1. Valve Body 2. Inlet Port 3. Outlet Port WORKING PRINCIPLE

4. Coil / Solenoid 5. Coil Windings 6. Lead Wires

7. Plunger 8. Spring 9. Orifice

The media controlled by the solenoid valve enters the valve through the inlet port. The media must flow through the orifice (9) before continuing into the outlet port (3). The orifice is closed and opened by the plunger (7). The valve pictured above is a normally-closed solenoid valve. Normally-closed valves use a spring (8) which presses the plunger tip against the opening of the orifice. The sealing material at the tip of the plunger keeps the media from entering the orifice, until the plunger is lifted up by an electromagnetic field created by the coil. Solenoid valves make automation of fluid and gas control possible. Modern solenoid valves offer fast operation, high reliability, long service life, and compact design.

RELAY CIRCUITS
A relay is an electrically operated switch. Current flowing through the coil of the relay creates a magnetic field which attracts a lever and changes the switch contacts. The coil current can be on or off so relays have two switch positions and most have double throw (changeover) switch contacts as shown in the diagram.

COM = Common, always connect to this, it is the moving part of the switch NC = Normally Closed, COM is connected to this when the relay coil is off. NO = Normally Open, COM is connected to this when the relay coil is on Relays allow one circuit to switch a second circuit which can be completely separate from the first. For example a low voltage battery circuit can use a relay to switch a 230V AC mains circuit. There is no electrical connection inside the relay between the two circuits, the link is magnetic and mechanical.

Relays are usuallly SPDT or DPDT but they can have many more sets of switch contacts, for example relays with 4 sets of changeover contacts are readily available. The coil of a relay passes a relatively large current, typically 30mA for a 12V relay, but it can be as much as 100mA for relays designed to operate from lower voltages. Most ICs (chips) cannot provide this current and a transistor is usually used to amplify the small IC current to the larger value required for the relay coil. The maximum output current for the popular 555 timer IC is 200mA so these devices can supply relay coils directly without amplification.

SMPS
Switch mode power supplies(SMPS) are an extraordinary array of high frequency alternative. These are the Switching Regulators offers higher efficiency then liner regulators. In addition the Power Supply SMPS can step-up, down and invert the input voltage

The role of a power supply is convert the mains voltage into a lower DC voltage which the components can run on. While there are two types of PSUs out there (linear and switching/switch-mode) WORKING PRINCIPLE A switchmode power supply consists of 8 main stages: The input filtering (green), primary bridge rectifier (dark blue), primary capacitors (yellow), primary switching transistors (red), transformers (orange), secondary rectifiers (light blue), output filtering (purple) and the feedback and protection circuits (black). In this we will look at each of them and discuss what they are for

INPUT FILTERING The input filtering has two main roles. The first is to prevent any interference on the mains from affecting the power supply. The second is to prevent any interference generated by the power supply itself from getting back into the grid and affecting other appliances.

The minimum recommended number of components for the input filtering are two coils, two ceramic Y-capacitors, two polyester X-capacitors, an NTC current inrush limiter and an MOV. The above left power supply (an Aywun A1-5000) includes more than enough X-capacitors, but lacks an MOV, whose job it is to eat up any spikes on the power line, so its unlikely that it would handle them too well. The one pictured to the right of it however (an NSCom P4-500W) doesnt have any input filtering whatsoever, so it would no only be very susceptible to interference and surges from the power grid, but would also cause a lot of interference. The fuse, while not considered as part of the input filtering, is often located in that area of the PCB. Its job is not to filter surges and interference, but to blow should something go seriously wrong such as one of the components failing shorted, preventing the shorted part from causing a fire. THE BRIDGE RECTIFIER This part converts the AC current from the mains into a pulsed, non-continuous DC. The rating of the rectifier will not have a huge effect on the performance of the PSU, but it can determine how much the PSU can deliver without causing them to short. To get an idea of how much it can handle, find its rating, multiply it by the mains voltage and multiply that by the PSUs efficiency (which is typically around 75% for a cheaper unit on a 120v mains voltage). For example, if the rectifier is rated at 4A and the mains

voltage is 120v, then 480W (4 x 120) is the maximum the PSU can draw from the mains and 360W (480 x 75%) would be the maximum theoretical output if the efficiency was 75%, assuming that the other components can handle it. Some cheaper power supplies (like the NSCom unit pictured earlier) use four discrete diodes instead of a rectifier. While this essentially achieves the same result, they are often rated much lower than a bridge rectifier, with 2A being a common rating. THE PRIMARY CAPACITORS These smooth the pulsed DC current coming from the rectifier into a smooth, constant DC for the primary switchers to work with. In a 120v power line, they are used in voltage doubler mode, where they are charged in parallel and discharged in series, so the output voltage is double the voltage coming from the rectifier. This doesnt generally put a lot of stress on them, so even capacitors from low quality brands usually hold up fine here. THE PRIMARY SWITCHING TRANSISTORS (SWITCHERS) These pulse the current into the transformer. Here we cant use the pulsed current from the grid. The first is that using current straight from the grid requires a physically large transformer, since the frequency from the grid is different from that used by the switching transistors. The second reason is because the duty cycle of the transistors can be adjusted to keep the voltages roughly constant even when the load and input voltage changes. They generate a lot of heat during operation, which is why they are bolted to a heat sink.

The 5vsb transistor as is actually part of a two-transistor circuit. They do a similar thing to the main switchers, only, they pulse the current onto the smaller 5vsb transformer. Some PSUs lack 5vsb transistors, since two transistor circuits are much more failure prone than ones based on a PWM IC such as a DM311. One classic example was the Bestec ATX-250-12E. The two-transistor 5vsb circuits in these PSUs would often fail catastrophically and the 5vsb voltage would go way over 5v, as high as 18v in some cases. The switcers are probably the most common failure point on cheap power supplies. When overloaded or overheated, they generally generally go out with a bang. The two explosions from this Thermal Master TM-420-PMSR were the two primary switchers failing in this manner..

TRANSFORMERS These are what actually change the voltage. They are essentially a heap of coils wound around a main core. In general, the bigger the core, the more current the transformer can handle. If the transformer core is overloaded, it goes into what is known as saturation, which often damages the switchers, causing them to explode as if they were being overloaded.

Like most PSUs, this Aywun A1-5000 has three transformers. The big main transformer, which generates the 12v, 5v and 3.3v voltages, the feedback transformer, which is part of the circuit that drives the switchers and the 5vsb transformer, which generates the 5vsb voltage. In some PSUs, the feedback transformer is replaced be 3 optocouplers. SECONDARY RECTIFIERS These do a similar thing to the bridge rectifier on the primary side, only allowing the current to flow one way, which avoids reverse-polarising the secondary capacitors. The rating of the rectifier is the maximum amount of current that that rail can handle. Some cheap PSUs simply use a pair of discreet diodes in place of a rectifier. The problem with this is that they are only rated for around 3-4A each, meaning that you will only be able to pull 6-8A from that rail before they fail, and most PCs nowadays will pull a bit more than that. Like the primary switching transistors, they get hot and are bolted to a heat sink. Unlike the switchers, however, they dont go out with a fireworks display when they fail. The output voltage for whichever rail it is controlling will briefly spike, damaging attached hardware and the rectifier will then short internally, and the PSUs SCP (Short Circuit Protection) will step in and shut the PSU down.

Generally we can tell which rectifier controls which rail by its position in relation to the wires. In most PSUs, including the NSCom P4-550W, there are 3 main groups of output wires, one for the 3.3v rail, one for the 5v and one for the 12v. The rectifier for each rail is located behind the group of wires which it powers. OUTPUT FILTERING The output filtering is intended to smooth out the ripple in the current generated by the switching transistors. The 3 main rails should have at least two capacitors and one PI filter coil, while the other two low current rails (the -12 and 5vsb) are often OK with just one capacitor and a PI filter coil. The NSCom P4-550W pictured above uses no PI filter coils at all. As a result, the ripple is out-of spec, which can cause stability problems and shorten the life of the PC it powers. Some even cheaper units also omit one of the capacitors, using just one capacitor per rail. This makes the ripple even worse. The Aywun A1-5000 (pictured below), however, does have PI filter coils, so the ripple will be much better.

The capacitors on the secondary side are put under a lot more stress than the two on the primary side, so it is important for long term reliability of a PSU to use high quality ones. When the secondary filter capacitors fail, the ripple will go through the roof. One PSU with bad caps we connected to our oscilloscope was an Antec SP-350. The two capacitors on the 5vsb rail were Fuhjyyu branded (which is one of the worst brands available) and both were bulging. The PSU made a horrible high pitched squeal when plugged in and the ripple on the 5vsb rail was 5v. Yes, five volts of ripple. Not only is this above the maximum 50mv (0.05v) allowed in ATX specifications, but more than enough to damage a motherboard.

FEEDBACK AND PROTECTION The feedback circuit is for monitoring the output voltages and adjusting the duty cycle of the switching transistors accordingly. The monitoring IC may also feature protections which shut the PSU down when necessary to avoid damaging it or the attached hardware. Over Current Protection (OCP) will shut the power supply down if too much current is drawn from one or more rails. Over Power Protection (OPP) steps in if the PSU is being overloaded, preventing the primary switching transistors from exploding. Over Voltage Protection (OVP) and Under Voltage Protection (UVP) step in when the voltages are too high or too low. Short Circuit Protection (SCP) kicks in when one of the rails is shorted by faulty hardware or when one of the secondary rectifiers shorts. Over Temperature Protection (OTP) shuts the PSU down when things get too hot and prevents the PSU from starting again until it cools down.

The Power Good (PG) signal is essentially a signal from the PSU to the motherboard that the PSU has started up, the voltages are stable and the PC can POST. The PG Generator IC monitors the voltages during start up and generates the PG signal when they have stabilised. Some power supplies lack a separate PG generator, but rather, they use a monitoring IC with a PG Generator integrated, so there will only be one IC. ADVANTAGES Change the output to a different voltage level then the input ( step-up or stepdown). Isolate the output from the input. Provide the user with a means to vary the output Can get constant output at variable input. Stabilize the output against the influence of: Source changes (source effect)

 Load changes (load effect) Temperature changes ( temp. Effect) The passage of time ( time effect or drift) Output short circuit protected

APPLICATIONS SMPSs are having wide range of applications some of them are Machine tool industries Security systems (Close Circuit Cameras) Where the size and weight very less is required Audio and video application Support supplies with PLCs.

PROXIMITY SENSORS
A Proximity sensor can detect objects without physical contact. A proximity sensor often emits an electromagnetic field or beam and look for changes in the field. The object being sensed is often referred to as the proximity sensor's target. Different proximity sensor targets demand different sensors. For example, a capacitive or photoelectric sensor might be suitable for a plastic target; an inductive proximity sensor requires a metal target.

A proximity sensor that measures current flow between the sensing electrode and the target provides readouts in appropriate engineering units. Usually, one side of the voltage source or oscillator connects to the sensing electrode, and the other side connects through a current-measuring circuit to the target, which generally is a metal part at earth or ground potential. Proximity Sensors are available in models using high-frequency oscillation to detect ferrous and non-ferrous metal objects and in capacitive models to detect non-metal objects. Proximity sensors are the most common and affordable solution for no-touch object detection. The most commonly-used proximity sensor is the inductive type, which generates an electromagnetic field to sense metal objects passing close to its face. This is usually the easiest sensing technology to apply in applications where the metal object to be detected is within an inch or two of the sensor face.

HUMAN MACHINE INTERFACE

HMI (Human Machine Interface) is a medium for information exchange and mutual communication between electromechanical system's and the user. It allows the user to complete settings through touchable images or keys on the user-friendly window. This not only offer's fast and convenient control of manufacturing automation, but also has replaced traditional controlling panel's which need extensive wiring.

The user interface, in the industrial design field of humanmachine interaction, is the space where interaction between humans and machines occurs. The goal of interaction between a human and a machine at the user interface is effective operation and control of the machine, and feedback from the machine which aids the operator in making operational decisions. The goal of human-machine interaction engineering is to produce a user interface which makes it easy, efficient, and enjoyable to operate a machine in the way which produces the desired result. This generally means that the operator needs to provide minimal input to achieve the desired output, and also that the machine minimizes undesired outputs to the human.

3-PHASE INDUCTION MOTOR

An induction or asynchronous motor is a type of AC motor where power is supplied to the rotor by means of electromagnetic induction. These motors are widely used in industrial drives, particularly polyphase induction motors, because they are rugged and have no brushes. Single-phase versions are used in small appliances. Their speed is determined by the frequency of the supply current, so they are most widely used in constant-speed applications, although variable speed versions, using variable frequency

drives are becoming more common. The most common type is the squirrel cage motor, and this term is sometimes used for induction motors generally.

OPERATION In induction motors, the stator is powered with alternating current (polyphase current in large machines) and designed to create a rotating magnetic field which rotates in time with the AC oscillations. In an induction motor the rotor rotates at a slower speed than the stator field. Therefore the magnetic field through the rotor is changing (rotating). The rotor has windings in the form of closed loops of wire. The changing magnetic flux induces currents in the windings as in a transformer, and these currents create their own magnetic fields. These interact with the stator field to create torque to turn the rotor. As the speed of the rotor drops below synchronous speed, the rotation rate of the magnetic field in the rotor increases, inducing more current in the windings and creating more torque. The ratio between the rotation rate of the magnetic field as seen by the rotor (slip speed) and the rotation rate of the stator's rotating field is called "slip". Under load, the speed drops and the slip increases enough to create sufficient torque to turn the load.

PELLET TRAY
These trays are used to place the pellets. It consists of 19 slots to fill up the pellets. The pellet tray should be properly aligned with the rod tray so the pellets can be further moved to zircaloy tubes through the rod tray by the pushers.

THE ROD TRAY AND THE PELLET TRAY ARE ALIGNED WITH EACH OTHER.

ROD TRAY
These are fixed in the machine. They are placed next to the pellet tray so, that the pellets can be moved from pellet tray to rod tray. Care should be taken in the design part that the angle between the two space bars should be 60 degrees. Such that the pellets can be easily moved into specified space bar

WEIGH SYSTEM
The weigh system in our project plays a key role. The weigh system is connected to load cell internally. The load cell measures the weight of the zircaloy tubes before and after the pellets are loaded and this data can be seen in the weigh system. The weigh system is connected to computer by RS-232 serial port interface and the same data is stored in the computer.

WEIGHT OF ZIRCALOY TUBES IS CHECKED THROUGH WEIGH SYSTEM

4. SOFTWARE USED FOR FX2N PLC

In this project for our FX2N PLC we are using MADOC software, since we are using Mitsubishi product it is named as MELSEC MEDOC softaware. In this software we are using ladder logic programming for PLC. The program length for PLC BASED SPECIAL PURPOSE LOADING SYSTEM is 1389 steps.

5. CONCLUSION
The SPECIAL PURPOSE LOADING SYSTEM is designed with latest technology, it is highly efficent. It gives the accurate output than a manual loading system. Now it has become possible to the system can load the stack of pellets into 19 zircaloy tubes at a strech. The loading time for the stack of pellets into 19 zircaloy tubes is less than 10 seconds. Since the PLC BASEDSPECIAL PURPOSE LOADING SYSTEM gives the accurate output within the seconds, automatically the productivity rate is highly increased.

6. BIBLIOGRAPHY
1. NUCLEAR FUEL COMPLEX website (www.nfc.gov.in) 2. WEKIPEDIA website (www.wekipedia.org) 3. PLC MANUAL website (www.plcmanual.com) 4. MITSUBISHI FX2N MANUAL (www.mitsubishielectric.com) 5. PLC MANUAL (www.plcmanual.com) 6. LADDER LOGIC (www.allaboutcircuits.com) 7. Switch Mode Power Supply (www.hardwareinsights.com) 8. SMPS Reference manual (www.9h1lo.net) 9. SMPS Design (www.smpstech.com) 10. PLC Scan Time (www.electrocam.com) 11. JOE EVANS (www.pacificliquid.com) 3 phase induction motor 12. www.webopedia.com 13. www.reference.com

14. www.reshelectronics.com 15. John R Hackworth Fredrerick D Hackworth Jr. programmable logic Controllers. Second edition published by Pearson education.Ltd. 16. Melsec Medoc Plus IEC programming and documentation system reference manual MISTUISHI electric.