GLOBAL ACADEMY OF TECHNOLOGY

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

SYNOPSIS ON

PC BASED (SOFT PLC) INDUSTRIAL AUTOMATION

SUBMITTED BY
NAME USN
AKANKSHA ATTRI 1GA14EE004
ANKITHA VENKAPPA VANTAGODI 1GA14EE007
HEMANTH K.R. 1GA14EE014
PRERITH S. 1GA14EE026

UNDER THE GUIDANCE OF

VENKATESH K.
ASSOCIATE PROFESSOR

PROJECT TO BE CARRIED OUT UNDER BECKHOFF AUTOMATION PVT. LTD.

 CONTENTS

• INTRODUCTION
• PROBLEM FORMULATION
• OBJECTIVE OF PROJECT
• BLOCK DIAGRAM
• METHODOLOGY
• ADVANTAGES
• EXPECTED OUTCOME
• ESTIMATED COST
 INTRODUCTION

• AUTOMATION IS THE USE OF CONTROL SYSTEMS AND INFORMATION

TECHNOLOGIES TO REDUCE THE NEED FOR HUMAN WORK IN THE PRODUCTION OF
GOODS AND SERVICES.
• IN THE SCOPE OF INDUSTRIALISATION, AUTOMATION IS A STEP BEYOND
MECHANIZATION.
• AUTOMATION PLAYS AN INCREASINGLY IMPORTANT ROLE IN THE WORLD ECONOMY
AND IN DAILY EXPERIENCE.
• WINDOWS PC-BASED AUTOMATION IS A PROCESS THAT ENTAILS THE USE OF
SOFTWARE TO MANAGE REAL-TIME APPLICATIONS WRITTEN IN C#, C++, .NET, ETC.,
THAT CAN PERFORM SUCH FUNCTIONS AS MOTION CONTROL AND MACHINE
VISION IN VARIOUS INDUSTRIAL PROCEDURAL ENVIRONMENTS.
 PROBLEM FORMULATION

• TO OVERCOME THE PROBLEMS ENCOUNTERED DURING MANUAL

ASSEMBLY IN MASS PRODUCTION OF INDUSTRIAL PRODUCTS.
• A DISADVANTAGE OF MANUAL ASSEMBLY SYSTEMS IS THAT THEY CAN BE
HIGHLY LABOUR-INTENSIVE TO OPERATE. THEY REQUIRE CONTINUOUS
MONITORING TO ENSURE THAT EACH TRANSACTION IS ACCOUNTED FOR
AND THAT PRODUCTS ARE MAINTAINED AT THE APPROPRIATE STOCKING
LEVELS.
• A MANUAL ASSEMBLY SYSTEM RELIES HEAVILY ON THE ACTIONS OF
PEOPLE, WHICH INCREASES THE POSSIBILITY OF HUMAN ERROR
 OBJECTIVES

• IMPLEMENTATION OF OPEN AUTOMATION SYSTEMS BASED ON PC-CONTROL

TECHNOLOGY.
• USING TWINCAT3.0 AUTOMATION SOFTWARE, HIGH PERFORMANCE ALTERNATIVES
TO TRADITIONAL CONTROL TECHNOLOGY IS DEVELOPED.
• SOFT PLCS ARE PROGRAMMED FOR THE BELOW MENTIONED ELECTRICAL
APPLICATIONS TO MEET A WIDE RANGE OF CONTROL REQUIREMENTS.
• APPLICATIONS:
• A.) ROBOTIC WELDING ARM - USE OF MECHANIZED PROGRAMMABLE TOOLS
(ROBOTS), WHICH COMPLETELY AUTOMATE A WELDING PROCESS BY BOTH
PERFORMING THE WELD AND HANDLING THE PART IN AUTOMOBILES.
• B.) AUTOMATIC MOTOR ASSEMBLY - USE OF PC-BASED AUTOMATIC ASSEMBLY
LINE FOR MANUFACTURING MOTORS USED IN POWER WINDOWS OF
AUTOMOBILES
BLOCK DIAGRAM
 METHODOLOGY
• AUTOMATIC MOTOR ASSEMBLY-
• SENSORS ARE CONNECTED TO EACH STATION OF THE ASSEMBLY LINE AND THE INPUTS AND
OUTPUTS OF THE SENSORS ARE OBSERVED AND USING THESE DIGITAL INPUTS AND DIGITAL
OUTPUTS, PROGRAMMING FOR THE BECKHOFF PLC IS DONE AND THE OPERATIONS ARE
AUTOMATED AND CONTROLLED USING HMI.
• OPERATIONS OF THE ROBOTS AND THE CONTROLLING OF THE MOTORS IS ALSO DONE
USING THE SAME PC-BASED AUTOMATION SYSTEM.
• ROBOTIC WELDING ARM-
• WELDING OF FRONT AND REAR CAR SEAT FRAMES ARE DIVIDED INTO 7 CELLS.
• EACH CELL HAS A WELDING ROBO ARM AND FIXTURES.
• FIXTURES AT EACH CELL HAS MANY ANALOG AND DIGITAL I/O’S.
• DEPENDING UPON THESE I/O’S PLC TO BE USED IS DECIDED AND DIVIDED INTO MAIN PLC PANEL AND
REMOTE PLC PANELS
• AFTER INTEGRATING I/O’S WITH PLCS, PROGRAMMING IS DONE FOR PLC TO CONTROL THE ROBO ARM
AND FIXTURES TO WELD A CAR SEAT.
 ADVANTAGES
• REPLACES HARD PHYSICAL OR MONOTONOUS WORK.
• HUMAN ERRORS ARE ELIMINATED AS THE TASKS ARE
COMPLETELY PROGRAMMED AND AUTOMATED.
• FASTER PRODUCTION AND CHEAPER LABOUR COSTS.
• AUTOMATION CAN BE MAINTAINED WITH SIMPLE QUALITY
CHECKS.
• CAN PERFORM TASKS BEYOND HUMAN CAPABILITIES.
 EXPECTED OUTCOME
• SINGLE AND MULTI-AXIS POSITIONING ROBOTIC ARM WITH HIGH DYNAMIC
REQUIREMENTS ARE PERFORMED USING SOFT PLCS.
• BEST PERFORMANCE AND DYNAMICS ARE OBTAINED BY SERVO DRIVES FOR FAST AND
PRECISE ASSEMBLY OF CAR POWER WINDOW USING SOFT PLCS.
• IN THIS PROCESS WE LEARN ABOUT TWINCAT3.0, INTEGRATION OF PLCS FOR
AUTOMATION USING ETHERCAT FIELD BUS AND PROGRAMMING FOR AUTOMATION
APPLICATIONS.

EXPECTED COST:
THE PROJECT IS CARRIED OUT UNDER BECKHOFF AUTOMATION PVT. LTD., FOR THEIR CLIENT CUSTOMER
INCITE CAMS CENTRE AND NEXTFIRST ENGINEERING TECHNOLOGIES AND HENCE THE COST IS NIL.
THANK YOU