Chapters

Chapter No-1:Automation

Automation: Automation can be defined as a technology concerned with performing a process by means of

programmed commands combined with automatic feedback control to ensure proper execution

of the instructions. The resulting system is capable of operating without human intervention.

The use of control systems such as computers, pre-programmed overhead cranes, automated

assembly lines, automated painting shops etc etc so that the load on human operators is reduced

leading to a better quality product with fewer overheads and minimal throughput time.

E.g. in the shop floor, welding is done by hand--now they have mechanical arms doing it. Same

with steel cutting, it is now done by lasers.

1.1 BASIC COMPONENTS OF AUTOMATION:

Figure 1.1 components of automation


1.2 TYPES OF AUTOMATION:

Although automation can play a major role in increasing productivity and reducing costs in

service industriesas in the example of a retail store that installs bar code scanners in its

checkout lanesautomation is most prevalent in manufacturing industries. In recent years, the

manufacturing field has witnessed the development of major automation alternatives. Some of

these types of automation include:

Information technology (IT)

Computer-aided manufacturing (CAM)

Numerically controlled (NC) equipment

Robots

Flexible manufacturing systems (FMS)

Computer integrated manufacturing (CIM)

Information technology (IT) encompasses a broad spectrum of computer technologies used to

create, store, retrieve, and disseminate information.

Computer-aided manufacturing (CAM) refers to the use of computers in the different

functions of production planning and control. CAM includes the use of numerically controlled

machines, robots, and other automated systems for the manufacture of products. Computer-aided

manufacturing also includes computer-aided process planning (CAPP)group technology (GT),

production scheduling, and manufacturing flow analysis.

Numerically controlled (NC) machines are programmed versions of machine tools that execute

operations in sequence on parts or products. Individual machines may have their own computers


for that purpose; such tools are commonly referred to as computerized numerical controlled

(CNC) machines.

Robots are a type of automated equipment that may execute different tasks that are normally

handled by a human operator. In manufacturing, robots are used to handle a wide range of tasks,

including assembly, welding, painting, loading and unloading of heavy or hazardous materials,

inspection and testing, and finishing operations.

Flexible manufacturing systems (FMS) are comprehensive systems that may include

numerically controlled machine tools, robots, and automated material handling systems in the

manufacture of similar products or components using different routings among the machines.

Computer-integrated manufacturing (CIM) system is one in which many manufacturing

functions are linked through an integrated computer network. These manufacturing or

manufacturing-related functions include production planning and control, shop floor control,

quality control, computer-aided manufacturing, computer-aided design, purchasing, marketing,

and other functions. The objective of a computer-integrated manufacturing system is to allow

changes in product design, to reduce costs, and to optimize production requirements.

1.3 PROBLEM STATEMENT (BATCH PROCESS):

Batch production is the manufacturing technique of creating a group of components at a

workstation before moving the group to the next step in production. Batch production is common

in bakeries and in the manufacture of sports shoes, pharmaceutical ingredients (APIs), food

manufacturing, inks, paints and adhesives


1.2.1 Automation of Batch Process:

The batch control system is used in a batching system for controlling the batching of a fluid

material from one container to another container. Control means for use in a batching system for

controlling the batching of a fluid material from one container to another container. We took this

project as automation of batch controlling system is one of the main advanced manufacturing

industries requirement .our project is totally based and focused on automated controlling of

different features included in batch process from industrial point of view such as controlling of

flow, speed, pressure, timing and also switching of electrical instruments. The automation of

batch control is very demanding and important in advanced manufacturing industrial system.

So focusing on the industrial demand and requirement we took the decision to work on

automation of batch control system using PLC.

Simple, convenient and standard-compliant automation More flexible production Shorter "Time to market" by minimizing engineering and validation effort Optimized plant efficiency Simple quality management Lower validation costs due to traceable changes of recipes

The main difference from other computers is that PLCs are armored for severe conditions (such

as dust, moisture, heat, cold) of industrial environment.The second distinction of plc is that their

hardware and softwares are designed for easy use by plant electricians and technicians. The


hardware interfaces for connecting devices is actually the part of plc itself and are easily

connected.

When deciding whether to use a PLC based system or hardware relay system designer must think

of several questions i.e. need of high reliability, increased capability and out put required,

possible frequent control logic changes, need for

rapid modification, similar control logic valid for different machines, and specially the cost. The

merits of PLC system make them suitable than relay for such applications where the above

demands are required.

1.4 INSTRUMENTS OVERVIEW IN AUTOMATION OF BATCH PROCESS:

Programmable logic controller(PLC) Programmable controllers or PLCs are solid state members of computer family used

integrated circuits instead of electromechanical devices to implement control functions.

A PLC can store instructions like timing, sequencing, counting, arithmetic data

manipulation and communication to control industrial machines. A PLC operates at different

computer rates commonly called the baud rate.

3-phase induction motor:

3-phase induction motor is the most widely used motor in the world for different

purposes. We found its used in both home as well as in industrial application. In our

project we are using induction motor for stirrer moving so the speed of the motor and

timing for the automatic on-off of the motor is controlled via plc.


When power is applied to an induction motor it runs at its rated rate speed. While in

many applications variable speed is required. for example, in different pharmaceutical

companies, different liquids and substrates in a recipe are shacked at different speeds.

This speed of the stirrer is directly proportional to the speed of stirrer.

Frequency Inverter:

It is a device, or machine that changes an alternating current from one frequency to

another, with or without a change in voltage or number of phases. Also known as

frequency changer; frequency translator. In our project we are controlling the RPM of

frequency via plc and made frequency signal set constant.

press control:

It is capable for detecting both pressure and flow simultaneously as well as automatically

managing the pump operation. it is totally reliable ,resistant and easy to install.

Solenoid valve:

A solenoid valve is an electromechanical valve for use with liquid or gas. The valve is

controlled by an electric current through a solenoid coil. Solenoid valves may have two

or more ports: in the case of a two-port valve the flow is switched on or off; in the case

of a three-port valve, the outflow is switched between the two outlet ports. Multiple

solenoid valves can be placed together on a manifold.Solenoid valves are the most

frequently used control elements in fluidics. Their tasks are to shut off, release, dose,

distribute or mix fluids. They are found in many application areas. Solenoids offer fast


and safe switching, high reliability, long service life, good medium compatibility of the

materials used, low control power and compact design.

Thermocouple:

A thermocouple is made of a pair of wires of different metals, such as iron and copper,

whose ends are welded together. The welded point is called the "junction". When the

junctions are at different temperatures, as shown in Figure 1, the thermal electromotive force

(emf, millivolt) is generated between them.

Temperature Transmitter:

When there is change in temperature the resistance of the thermocouple is changed and there

is very minute change in voltage, which is round about 0 to 20mA. This small voltage is very

minute to be sensed by PLC

Chapter No-2:Batch Process

!"##$

% &'(&''&)*

+&,''-%%+*%

& & . / '% 012. &% &'. *.

%%,1&&*%.(//%/3%/3

)&/'/&./'4//)&//)%+4-'/4

%* / '. % % / ' +/* % , '

5 / % &'' & 4 +) + 6 0+4 )

(.*2/4/

+%/3+

//&)'%,/4&&%/

!"##7!81!9$

'/4%)'%+&

'//%+'%/%4&

&'&+/./#/%%&4)

'%&%&%&%"%.*)

:+;


+%+4&%'&+'/&)+4

).%,%/&%+4'/)&/

--/,%%)//

%&.,/%/4%& //)%

) , & +' %+/4& )'+)

%'%-%//4+

' 8' & &' + +/ , &

'

'

2.3 REASONS TO AUTOMATE BATCH PROCESS:

>,'+/)4.)*?%%

>@%%%'&4(

+4%-44@/,'&*.%)

'

>&&4%/+/4-&/

,'4%/,4.%,.(/4

>%/''+/+4'./&/-+/4

4%

>@%&,'%,4%,+%/,'3

> *) -/4 ) 4 ) % % % -%. &/ ,%

///&


#9A A#=! !9 !B$

9#1C1#3

9#1C1#3#

9#1C1#3

9#1C1#3/3./%%&'&%/4

B@&/*/#/4.

='$/#/4

+,&')%&&/,/&'&&/4

/.//4&)/&/,/


='$#3B,/)/

=')-//&&/,/.+-

B,/$,//*/4'0#82/'

0 82

B,/$//+4&'40B18#2

B,/%4//4

B,/$4/(

#%,%&/%/&-'%%+)+4

%&'41)%.%%/)&+)#B,/

%


='$1&"-')B,/D

,% %& & 8&' ! 8'. %/ # B,/

,&/*%%/%&/)*

(%&%%,%,+/4&%

='/

'DB'


9#1C1#3#

# %& / ' % ' &)*. )

%&*%%+/%&/-+/4&(.

% ,% & %' % '' 3/% &

%/" .8"#.%/%

%% / ' 0%/52 % ,% &)* &

02E) %'%4%%4&%'

4' /# )&/ %% & 4 $ +. .

%

%'#%%.

%&%

/%%&&(&/+4+?'(&

/%%&',,&%&'

&(

# @ ? %% & &). (. %E @ )4 & *'. %'

/4 7%%' # )// / %' + %' %& %

B,''*)/%'%-%%%)//+/4+ %&4

%. * %,/ . % / % %% &//

%/,/))4&)%

# / %4 , %&% %&/ & + /. /. &

%%0&)2#.+&)'%,'%/

/.)''+/&/&)&/


!

"

6@//%&,4*(%'/.+ %@

)$

/+&//4/0%,2

/+&//40%,2

/ + + & + 0) +) &//4 / % &//4

2

='$&/

# ) %'% %/ // /,/ & . %% + /% &//43

%4//4/4F4'+)

#$

+/'+/4 / &( '& / '&

%% %, & *' % 0 ) (' )* 3

&'/2/%,(+,.)+&/4+,

),4%&&,%%*&


='$# %"(/

1 &' . & * & ( /. &'

&/-+/ % /' $ ' &4 %'

(/+%&//+/%&&(.+%

( & % % #//4. ) ' G.

%/.'G%*'%/4

%&

! & *4 & # +/ ' & 6 / //

'&%%&//

%&.&/,/+'//%(0(2

%&.&/,/+'//%(


='$",4'*1

1@ %/5 +/ + &/-+/4 % & % (

/0&/%,/4%&)2

!)$

%'#.%&%$

4 & & (/4 %& % ( & &

%1)%.//)+'%0)/2'(

*%

)

%4/,/%+&/)3/,/1%&)

/%(.%(%'*%),.'/

//4 % ) & *)/%' & / ( )//

&%


& &' 1 //4%,% &'/

& % & &' % ,%

/,/&%/4&/'3%%/''%&&

/'' ) 4 ) & & // ) / 6/ 4 // +

&/&(.4+&3''

4%

Figure 2.8: A Recipe Explosion

'% ' % %,% & '/

8 %% ( 4 /. '/3/% -' ,/

%3& & (% & %/% %/'.

((


%'/.&+ 14&%

%&%4+%&4&+5.&

) / 3 0'. 42. / ( + % / /

(%,%/+//)%*''/'4

Information in a Recipe

* G %, & 0 1A. . , +. ,

4.,/.2%4

%$ )$

G 1& + & ( 4 *

+&&+0#'/%%@//4//&

(.(4//4%+%'/2

GA&'4&4'.%//4

:;,%%/4

+GA+0'.'%.(2.

0'.'.'%&.-'%2.%0

% % (4 /' & '/ +2 =/ + % %'

+)%&&%%&&%:'%;%&%+4%

Recipe Procedure

The procedure explains how ingredients (raw materials) are to be combined, reacted, or

otherwise processed to make a batch. S88.01 defines two models for representing recipe

procedures:

, & '/ % %/ & %+'

.(


, & % / %/ &

%+'/4/(

Figure 2.9 : The Procedural Control Model

%%& %/'/

.%'%('%/4

!/4%//)%+,48//%

/4&%./'4,%&&

%%&%/)'/!

//4,/,*'/+'%'4&4/./.

+/'/'B*%.%%/4,

/

///&%///3%*

& ( % '//4 %%. + 3% &.

'''%''*#/4.)*&//

/0%.%.%2/4'.'5.%%


)%-

Figure 2.10 : An candy Recipe Procedure

Figure 2.11: The Make Mix Unit Procedure


!

//&((%*+#

%%+(%*+//4,

.%%&(%*/+//%

1)%. // 4//4,% +%& (4

*+6/+%.%//4//+%

//4+'+4',0/'(,/+/2

(d) Unit

' , &% ' //% 1 )%. + '

+'%.&.)%%,/4

% %7/4,//*-'*.+%@

)4%&&?,/

$ .

/%+(46/.&&%

1/&+

+ / ) . ) + % /// ) //

%(//4'

=%3*'&

,).%1@%*+/.&4+)&


!9#1A" 1!9!=##9A A=! !"##$

#&E#&1)

&)#&)

#

+ + /. 3/ ' 6/ # /4

/+/.'&+4%+/

//+/%&+/'%

%%%%44%

%/

8/%+,/+/

4,%+/&,

%?+%%'/%'+

7!81!9!= !"##61B$

&&(,,%&/%%%%

%/4&/)#%%%+/+%.$

7&4/+/4&/02/&%//0

++4%'%%4+'&-2

%?&-'/?4&//%%5%?

7&4+,&@0'-%%%2

/)-,)&+,%/))


&(% 5 &'

.)3/)/,/.%&(&

/%/'&%,%/)/+,

( & +, % +/ & + ?

&%%&%&&/&-&'+//'//0B2

/&. ) /4 , /&% % & / & -, ).

&&%+4#+%/

"H71 "8"9#=! 7!819I !"##!9 !B61B$

%''%+,/&'//&

),%&%&//)'()+///%&4

/%+-%B%/&/4// / / &

/%'./%+-%B/&.%3/G&.

&-/(%.'.+'%,'/%

+-%/&

/%+%+4=&+/)/%

++/4++/%B/&'#=.)

* &,&'+/-&+/?)

/%' #%%/% * %.) )%

+/ %%' ' & #= +4 . % )

-/%+,=+4&+/


4)//,+%%%/&/G)%%%&)

/,/$ % /,/ ) % % % /,/.

)4/,'/,/)&%%&

)&&&?4&/0//%%5%2

?))/)/%+%

+,&%///%/4)#%%.+)

%&%/,8%/'%&+&&%

+,/%(/-&%,%//&

%/

#%%'&+/&/-

&. / + && ' ' %/ /

/%+%%&/

/ /% + %'%

, ' +/ /,/ & ++/4

'+/B'

//0B2

93$'+/B'//

)./),,0%./1.2").%)

19 !A71!9

1/4+&'4%%)%//&

%4%/'4/4+%&/%////+%

/41/4*//'//%%,/&/)4

+',/.'+/B'/

.///%

. /% + &

&/4. ' '% %&//%,//&

4+/&' . ('. '. '..%/.

% . / %/ % B 3&%/4. 3

+% /5% / '+/ B' / + //

% ' ' &-% , ( & ,/, /'/ %

%

" !B"!=" !I 88B"B!I1!9 !BB" #0B2$

1 % 4 / /4 '%% & / 4 6 /

/'0%/42-.B/4&4

' &/% %, &%+*'/ 1)//%%'/' %

&+%&/%%,

'+///,4%&),.B+'&/%/

)//4%'% +/ 0B/&2% &'

93$'+/B'//

4&/%%,0C

/)/%2'+//'//

%///)%'+%/&/4%//

='3///%'&B/

='$ B//%'

B+%//,*&)&4+

%')

//%'/&/-

13.4

1//'&%4'/4%%'+/4&B%'/

& , 4 & '%/ &/%%,3/ %,!

%. &%&)*3.'&,'.*'% /(%

/,/ % 4 . B )// , '/ & & ' %, /*

-4)./)./.%/,/%4&'/

93$'+/B'//

B)/%+&!9C!==/'/'

4/%B4,//4/45%)& &

&/% %, # & /4 //% %, . /%. /4 %.

+55 % ),. %, / /.+55 %/ /4

&&4'

B#1#

B&/'7072'. -,4%/

4.1%!1&'%/.)%/4

%&/%1C!%,

'/B)'/&%,%.

% //4 ,/,'&'/ &

%,

='$8%/&B

93$'+/B'//

/'072',//B,&//)'.)='

J

J 44

J)/4

,B/*A'.//'+&/4/'02/

' ' /% ' /% ) ' 4 /' /,

%&'%/.&/,/'%

40'2%/)/'%,'

%/

!9# 71!9!=B

#B'%'/.)%/1'%B//%

+-+*B+&//51&'%B,/+/)+/

% 8%/ B & / (% & /- /

/./%%+/%+48%/B/%&//)'$

37%/.'7%4

3)/4%/.,%)7%&,%)%,

31%%/01C!%/2.//)B%%/

3*+.7%/-'%)1C!%/

93$'+/B'//

B4)//%%/%4

''43'%%B7%/K4

''%+/%.%%/'/(B)//-9)*

&//)

'&B%C//%+%/

!&%,//)%4%C%'+4

='$8%/B1%

B1"7 "$

5"(,

7 %/ / ' % 4 4 /% !8

0'+/ %3/4 42 ' B@ ' 4. %, '. %

/'.% 8)3)'%)*'%%84B

93$'+/B'//

/&&,+/4%/.)/''%7%/*4

&3'%%"" !80///4+/'+/%3/442

,+/4%/ /4.B,%/%&/4=/4/*

"" !84-+))%'/4=/4%

,+/ 4 %/ % & ' /% "" !8 4 . + &/

4/+/7%/.)//4+*& 8

7&B4402-4@%%C

.+-%&/&&

%%',,&4

='84%7&B

A' . 7 / $ %. . % & &/%

93$'+/B'//

%,, &. -.&. /'% 44.

%).%.%,,&&(//4%'

.-''4.%%'*)

'

5"*%)6.)0(#

A',44/.7%/%%)1C!%/&%/B

7%/

%&1C!%/,&///%//%+1

%/4.++*/%*.%//B%//''%

/*+%,%)%

1C!%/

5"*%.7%)#(8

)/4%/,,/+/)%)/,/(%+47%1C!

%/ /4 7//4. ,/+/) 4//4 5C

93$'+/B'//

='$)/4/4

4

93$'+/B'//

59

)//'1C!%/%/-'&%,/*3

'7)%&%/.%%/

/%)*#//4.&%/%

& , )* %/% / 7 % &

%/8%7%/+

%%/4)*.

&%/ %% /4 & (-% 7K+/3+/

6B).4&/&3* /%'+ %)

4%/ . % 5 %-' )// + &%

4/

" 1#1=791!9#!=B$

'+/ // /4 %&% +4 9/ "// 8&

09"82 %'/ / %, '+/ 4 %

/&& /'. (.'.'.%/

%1%&%&&/-%/

&B4()$

!1&/%'+/+4//))%''3

&/%))'%'+*&&

!1'%&B//''.'.%4&3

'4&/3%''/''

93$'+/B'//

!14%%01C!2%

/&//)

/'%/4))//%'

9!1,%*'%%'

521+%B)//,%&&'+/4.'

%'/')&%.+4-/%,%/4

'-

:21*'%/4B%'%)%.%4.,+.

%&%&4,

;!1'/+/4I//4B%'%&&/.+%/

)%,4&/*&&,/4

>"#!=B

'+///,/+///%5.,')%&+/!

/)%:/4/.:)1C!%4+/4'%/',4

//. ) /4 / / 4+4 &' ,4& / %%

(&6-/&)%./%''/%/3'+/

//.4/)/ ,'%% %'*4

/'+%&*'+////&&4&.%'

% ) %+/ / 4 % ) // + &

%&%&/

93$'+/B'//

;,1). #

8B%/(/&&)%1C!%,.//,4

/#B&/%/'1C!'&0'.'

,'2=')4///

;#, #

#/////4%/(!9C!==/&/'('%'

&B./')//.)%/4%&%,%//&//

!&.%'/3+%//+//%%&&//B

;,%41(, #

8% B % / ( 1C!. )// /' /. %

/%+/ 1'/ // ', &/-+/%)

%&)&//,/4%

;9)/%#

B'//%&/%/*.)(-,%/.%

(. % ' = &) //) % & /-

/

;5

93$'+/B'//

,/, ,/' /4%. + & ()// ) /

'.

&4-4/4(//&4%/E&.%%&

/4+4

'%,

A"# 11!9!="B#!=6 "$

=.#

7%/&B),4%&&'4'%

.%/)/''%7K4

'4'B))%.3')

B)%%.%%%+4

'/

'

/'//)'%%BK4#&

+/4%,)BK)%

%B'4

*B3',4%&&/4&)43'B

'4-/5%.%%/4

*B-4/(/'B%",4B

&4/%.'4/)%'

)%')/4/-1&)%'3,/+&

+'%0&4/*//4/2.B)//%/4&/.%

'&&/'.B//4%,+&

'

=(>

7'&'%&'%)B4

93$'+/B'//

+%BK 84+4''''.)

+%

%&BB,3'4&&3

%+4)/%+4/'3/&+43'

BK4/''%'

=

B/''%%5%+41"&)//%/''.)/''

%#=

1//%/''

2BA0B%%A'2$1'//''+%/4/%%/'

+2=A0=/*A'2$1'//''&%''/%%&/)

'&+/*33+/&)/

/''

21B01B2$1/)3/,/K+//*K/''+%///''

+2#0#%-2$1'3/,//''B4

#=0#(/=21'//''&%'(/+,&

/41%&%&'/(

%,3%,

93$'+/B'//

B !I 8819I$

44%)./1

LB%%L%'

A'//'&

3.9.1LADDER DIAGRAMS:

Ladder diagrams are specialized schematics commonly used to document industrial control logic systems. They are called "ladder" diagrams because they resemble a ladder, with two vertical rails (supply power) and as many "rungs" (horizontal lines) as there are control circuits to represent. If we wanted to draw a simple ladder diagram showing a lamp that is controlled by a hand switch, it would look like this:

Figure 3.6 manually switch controlling of lamp

The "L1" and "L2" designations refer to the two poles of a 120 VAC supply, unless otherwise noted. L1 is the "hot" conductor, and L2 is the grounded ("neutral") conductor.

93$'+/B'//

3.10 SPECIFICATION OF DELTA DVP-SS:

The plc we are using in our project is dvp SS series The DVP-SS series provides a 14-point Main Processing Unitand allows to expand units with 8~16 points. The maximum input/output points could be extended up to 128 points. Since the power supply unit is independent of the main unit, and with the volume of the device being smaller, the installation of DVP PLC is thus easier.This is an OPEN-TYPE built-in PLC, and the PLC is certified to meet the safety requirements of IEC 61131-2RS(UL 508) when installed in the enclosure to avoid high temperature, high humidity, exceessive vibration corrosive gases, liquids, airbome dust or metallic particles. Also, it is equipped with protective methods such as some

special tool or key to open the enclosure, to avoid the possible hazard to users or any damage to the PLC

93$'+/B'//

Figure 3.7 : Product profile and outline

3.10.1 Wiring and Specifications of the Power Terminals:

This PLC model uses DC input power. Therefore, make sure that PLC is connected to terminals 24VDC

and0V (power range 20.4VDC~28.8VDC) when the power is ON. PLC will stop the operation and

output will be OFF whenever the power input is lower than 20.4VDC. Consequently, the ERROR LED

will blink swiftly.

93$'+/B'//

='$6'&)/

?71

)4&)'$#19M#!7 ".%%)4&&'A'/A

).)%&%&//)$

A4.)4&)'A4$#19M%#!7 "

='$C)'

93$'+/B'//

?"13.)"

/&B&'///%&//)$

: ;N:&%/4;O:@';O:%/4;

+/ &B

?"

+%%/%&87&//4/+/A"B

A

93$'+/B'//

+(21.2#%1+1"1.2#

+//&

6B#&)

0B%%B'#&)2

Chapter No -4:WPL Software

4.1 INTRODUCTIONS AND SYSTEM REQUIREMENTWPLSoft is a program editor of Delta DVP series PLC for WINDOWS computers. In

addition to general PLC programming and WINDOWS editing functions (e.g. Cut, paste,

copy, multi-window display, etc.), WPL Soft also provides various comment editing as well

as other special functions (e.g. register editing and settings, file accessing and saving,

contacts monitoring and setting, etc.).

The following system requirement are must to install WPL software

Windows 95/98/2000/NT/ME/XP/VISTA operating system.

Pentium 90 and above CPU.

128MB or above (256MB and above is recommended) memory.

Capacity: 50MB or above hard disk.

CD-ROM drives (for installing WPL Soft.

At least one of COM1~COM8 connected to PLC RS-232.

Figure 4.1 WPL soft


4.2 INSTALLATION AND PROGRAM EXECUTION:

WPLSoft will be installed in the default directory

C:\Program Files\Delta Industrial Automation\WPLSoft x.xx". Double click WPLSoft icon

to execute the program. The WPL editor window will pop up, There are File , View,

Communication, Options and Help in the toolbar when executing WPLSoft for the first time.

Figure 4.2 opening Window

Title bar: Displaying file name.

Menu bar: There are ten items in menu bar: File, Edit, Compile, Comments, Search, View,

Communication, Options, Window, and Help.

Toolbar: Selecting editing tools by clicking icons directly. There are four types:

1. Standard Toolbar:

2. PLC Toolbar:


3. Ladder Toolbar: (display in ladder diagram mode)

4. SFC Toolbar: (display in SFC diagram mod)

5. Debug Toolbar(display in simulator debug mode)

Working area : The area for designing and programming. Users can choose Instruction

editing, Ladder edition or SFC editing as their custom setting.

Status row: Displaying messages, including replace/insert mode, coordinate, PLC scan time,

program size after compiling, Communication indicating LED (blinking during

communication), PLC status (RUN/STOP/HALT/ ERROR), PLC COM port number(baud

rate), PLC models, etc.

4.3 SETUP

After executing WPLSoft, users can open a new file for PLC program design. Program titles,

PLC Type, program capacity (refer to the specification of PLC model name and program

capacity) and file name can be set in Select a PLC Model window.

When the above setting is finished, 2 sub windows will pop up. One is Ladder Diagram

Mode and the other is Instruction List Mode. Users can choose their favorable editing mode

for programming PLC instructions.


Figure 4.3: Modes of Programming

4.4 LADDER DIAGRAM MODE:

Start up WPLSoft, and click New to create a new screen or click Open to open an old

file. Then, users can enter into the editing environment of ladder diagram mode There is a

ladder diagram toolbar shown on the top of the ladder diagram mode window. To create and

edit a ladder diagram, you can click the icon on toolbar directly or move the editing block to

the proper position and enter instructions.

Ladder diagram

Figure 4.4 : Example Ladder Diagram

Ladder Diagram Mode Instruction List Mode


4.4.1 Operation Steps of Editing the Ladder Diagram:

Table 4.1: Editing the Ladder Diagram

After the ladder diagram is completed, you can compile and convert the completed ladder

diagram to instruction codes and SFC diagram.

4.4.2 Ladder Diagram Editing Instructions

WPLSoft provides several brevity codes for yours to input basic Instructions more quickly

and conveniently when editing a ladder diagram.

Table 4.2: Shortcuts For Editing


4.5 INSTRUCTION MODE:

Instruction editing environment looks like this

Figure 4.5: Instruction Mode Window

Type a complete PLC instruction when entering instruction mode.

Input Operation Example

Instruction programrefer to the following table and input instructions

(0000) LD X1

(0001) OR M0

(0002) OUT Y1

(0003) MOV D1 D2

(0008) END

After an instruction program is completed, it can be converted to the ladder diagram and SFC

diagram through compiling.


4.6 EDITING COMMENTS:

In the ladder diagram mode, there are three operating modes for editing comments: Device

comments, Segment comments and Row comments. However, while in SFC mode and

instruction mode, only EditDevice Comments function is provided.

Edit Device Comments:

Figure 4.6 Edit device Comment Window

4.7 COMMUNICATION:

Before proceeding with the communication, please make sure that PC COM port (RS232)

and PLC COM port has connected successfully. WPL Soft provides various tools for

operations, such as device monitor, read/write register data to PLC, modem connection,

communication setting, etc. It is convenient for users to edit, monitor or test by WPL Soft.

Click Options > Communication Setting

When communication setting is completed, users can start to read the PLC internal program

according to the following procedures

Click Communication To read data and retentive range from PLC, select PC


4.7.1 Write PLC:

1. Users can transmit a new program to PLC by clicking Communication > Transfer

Setup or click icon on toolbar or using keyboard shortcuts (Ctrl) + (F1).

2. To write data into PLC, select PC => PLC under the Communication Mode when

the transfer setup window appeared. Decide the write-in content by checking the boxes of

device comment, password, retentive range, default value, and RTC.

3. After clicking OK, there could be a Password Setting window if the PLC requested a

password. Users are allowed to read the internal program once with correct password.

However, an error message will appear with wrong password.

4. WPLSoft will transmit the PLC program from the start to the first END instruction

and write the program into PLC.

4.7.2Verify with PLC:

The function can verify the PLC internal program with the editing program in WPLSoft. If

the WPLsoft editing program is different from the PLC program, WPLSoft will send a

warning message of Verification error!! (as shown below), and if the two programs are the

same, WPLSoft will send a message of Verification is completed!!

Run/Stop PLC Click Communication > Run or click on the icon to get the dialog,

then press Yes to set the PLC in RUn

Click Communication > StopN condition or click on the icon to get the dialog, then

press Yes to set the PLC in STOP condition.


4.7.3:Communication Auto-Detect

WPLSoft editor can auto-detect the PLC communication speed.

Figure 4.7: auto-detect the PLC communication

4.8 SFC EDITING ENVIRONMENT:

SFC (Sequence Function Chart) is one of the programming languages defined in the IEC

61131-3 Standard and is also one kind of the diagram editing mode. However, the whole

structure of SFC diagram looks like a flow chart. In fact, it is to utilize the Step Relay S

within the PLC.

Start up WPLSoft and click File > New to create a new screen or click Open to open

an old file. Then, users can enter into the editing environment of SFC.

Figure 4.8 sequential function chart editor


4.8.1 Basic Operation

Table 4.3: SFC Editing

4.8.2 SFC Editing Environment: In SFC mode, up to 16 columns (horizontal direction) can

be used for programming, whereas there is no limit of the rows (vertical direction). Every

dotted cell stands for one SFC symbol, and therefore, a maximum of 16 columns could be

displayed on the screen in the horizontal direction at the same time.


Figure 4.9 SFC Environment

4.8.3 SFC Editing Instruction

Convert SFC Diagram into Instruction Codes through Compiling: (If users want to display a

ladder diagram, the SFC diagram needs to be compiled into instruction codes and then

compiled again into the ladder diagram.)

1. The SFC diagram is compiled to instruction codes .

2. The instruction codes are compiled to the ladder diagram

Figure 4.10 SFC Editing Instruction

6B#&%+//4$#=%.B%%%'

.A,


4.9 SIMULATOR:

The simulator provides users the program testing function without connecting with PLC.

However, the actual result might not be completely the same as connecting with PLC. The

program should be tested on PLC before running in field applications.

When simulator is activated, the WPLSoft window will be shown as below. The icons in the

frames are simulator functions.

Figure 4.11 ladder monitoring

When simulator is activated, users can perform communication functions such as monitoring,

program download/upload without setting the communication interface first. The operating

mode is same as the actual PLC connecting situation.

4.8.1 Simulator icons:


4.8.2 Introduction to the Debug mode

Click icon on toolbar to start debug mode. Users can switch between Message area and

Debug Mode Monitor Devices area from bottom:

Figure 4.12 Debug Mode

4.8.3 Functions of Debug Mode:

1. WPLSoft will write the program into simulator when debug mode is activated. In

addition, the scan time will be fixed and set to 100ms. Users can also set the scan time by

D1039 according to the approximate actual scan time of PLC. In debug mode, users can

set several break points in ladder diagram mode and instruction mode. The program will

stop at the break point when executing Scan Run.

2. In ladder diagram mode, right-click to set the break point on the instruction pointed by

cursor. After setting, there will be a red dot on the left of instruction.

3. In instruction mode, break points can be set by right-clicking as in ladder diagram

mode, and the instruction with break point will be highlighted by red color.


4. In debug mode, there is a window of Debug Mode Monitor Devices area in addition to

message display area. Users can monitor the status and values of devices, set the devices

to force On/Off or change present values.

The run time of timers and counters could differ according to the efficiency of users PC. The

working behavior of timer is same as ES/SA series PLC.

19# 78"9#D

A"

93$1DA,

"##!9 !B$

/ %, ) ) ' / / & &

%%/A,'&4%/%//'?.+/&

//4 %' + &/). )// //4 ''

1/%/-*4.'

&)'

=%/4.//4/+/..%4//

='$ /

5

/%/-*4

#%%)'%/'&

8%'%/,4

93$1DA,

#&)'.'&%4

'

&&&)'.%3&

5"+

8)/4,/'

93$1DA,

1/+%%%,/(/&

& - ' 0 +2 ) %' )4 +

5%&

5(

1/./&//)'+4&B

6'/'-%&+&B*

#'%'

,,/&''0'2

,/&&/)+/))&/))

59

93$1DA,

='$ &/

551

%,+%%/4%&

1& & %, -% + 0 82. // %

+)%%,/&

9+%+)%%,

1%%

&%,/+4&+//

,/,%&/-+/+0&'2

&'%,*/4%

='$ 1//&/

93$1DA,

55 %

1 %% /)4 & // & / ) )

'&.(///.&%,

0

93$1DA,

""#"19A71!98!! $

3 % . / //% 4 . /4

%4&%//1/.(/3'%'

)%/4%/%//

5.

//&)+&

&-%&.3)%'/%&%'

//

+) %

%% , ' & % # % % & '/4

'5+/,%'/)%%4%4/

5#

& %,%/ )%' ) ,/ %

&&+4//'/&R6

% )/4. '

)// &'5' )

)=///+&N5

'4

93$1DA,

%NC3#4%5)"

5)

%)(/3'&/%4/%/

*')/+)?%&+4'&/%

'&3%/&%

& &%,4/4//%, 1

//(K)%')/%+%%+4'&/%.)

*/3%

+/$4/4%5

#4%Q'5

='$/%(/3'3

93$1DA,

%/*&%%4%

% 0' )%'2

%./%%%%

,/' % +) %

'%&4&/%

'+'%&&-&%,(

&/0+2//%L*)L

/ 4%& 4 &/%. /4 //

3( 03/% /2 1& ) -/4 4/4. ,/'

)/% /'+ %%. )/% &/).% )/% /'+ 4

(

A'%&%%&&+)

4%%/%%//%%/%3%%/.

,/'%%)%''.)'%/

(8/.%(3

% /* &. &% %

0%4 %2 % /4 ' //4 %'

&'%+4)/4 ,%,

& & ) .

%/

93$1DA,

59#

%&&+)4%%%%//%

% '//4 -% A%' 5 & . %

'/4Q#/&&%

='$ ,/'7 /&&/

93$1DA,

,/'&Q%/&Q%%,/'7 )

+//1%.*N%N.)/

/ ' &/)& &%/3/&/+4'

' 0' 2 ( / * %' %

+,+%&%+4%',),

//4%&

&//)'&//%$

55.

!''/&+,&$

J% J

J)& J)

J&&4 J/

93$1DA,

='$!'&%&

N% N4%

N) N)

SN&&4 N)&

1N 1N%

N/ N%)

%/4/'/4/%

'/4//4/%

%%%*4//4%',/%

S ! S -+ " % / +, /&3

/%1'//4*+/)%)

1 1

+'

' '/4 /&3/% /) /&3/%

%/4/)/4/+3/%1!

93$1DA,

'/4/%'&3/%)

1,/%'/'/4&//&

#&&4S%)&,?&&&&4

&.*)/%'&/ /%,/,4,/%

&&4%' 1 / /% '4+% 1%%.

/)3% ) & // '3% &

//45%.'3%/4/-,.+4//

= "H7"9>19

93$1DA,

5"4

='$A'&1,

57

='&'

R

S

T

Power supply

I2

I3

I1

Frequency setting

FW

RE

XXRSC

CIRCUIT

CONFIGURATION

IM

Frequency

FM

C

FM

C

FVR-K7S

93$1DA,

T 1.1.1/4

M)'

& / 1

%1)//,%%?/1%I9A'%&O

93$1DA,

5#$

+/$&&,

93$1DA,

9"781

93$1DA,

59+

2C/&,/,

2-///%,/&..)/*'

2 '/' & /' 4 +) ,/, % ,/,

/'+/4

2

93$1DA,

+&%//%%&&+)?),.

% %% & ) % ,/ & / % & +

%)

='/

556"

9//4,%&&/%+//%

/01"2%C/%%./*9#1&7#.A19&I4%

V1#

&V/%/'5%/+/%/.'

+/+&%//

/%&%+44.&-/4/,

%',)%&4/4&/6?'

/%?.,&,)

93$1DA,

/+%+,%%'.

/+,%%'/&&/+.

%-%.4//5&)%1/./4

+/. / )4 & /

/. /' &(/4 ) /. /* 4 9

0/C/2 /. ) -% , /' /& 4 M

/-%5'A19/%47%B17#.46

%,4'0RR=2

%% 4 3& +/ & /. &% R

0R=21)%.&)/%?R

5.5.2 Selection of Thermocouple: Choose your thermocouple based on the temperature range and accuracy required. Some

thermocouples, for example Type B and R, use expensive materials - platinum and

rhodium.

Some thermocouples generate only low emf at a low temperature range.

(1) Application temperature

Some may think that the higher the temperature range, the better the thermocouple. If you

choose your thermocouple type only by the high recommended temperature range and the

upper limit, it may be expensive, or you may find unexpected error at a low temperature.

Choose the thermocouple whose recommended temperature range agrees with the

temperature that you would normally measure in your application.

(2) Environment

93$1DA,

Choose the wire materials which withstand the aggressive application atmosphere

(oxidation,

corrosion and others). A thermo-well is usually used to protect a thermocouple,

mechanically

and environmentally.

(3) Accuracy

Choose the thermocouple whose accuracy class meets your required accuracy

5.6 Temperature Transmitter:

When there is change in temperature the resistance of the thermocouple is changed and

there is very minute change in voltage, which is round about 0 to 20mA. This small

voltage is very minute to be sensed by PLC so in order to have a sensing voltage level we

use temperature transmitter, which converts the resistance into current of 4 to 20 mA.

Figure 5.12 : Temperature Transmitter

93$1DA,

These transmitters are the microprocessor-based controllers combine a high degree of

functionality and reliability.

These controllers also provide extra features such as

Motor Position Control

Phase angle Power Control

Set point Programming

A"#1I9D

18B18"91!9

93$A'D/

6.1 CONTROLLER PHILOSOPHY

The controller is designed to be multi-tasking. It can perform more than one task at a

time, for instance A57CSTD can heat the machine on a gradient whilst simultaneously

Dosing the chemicals from the Addition Tank. The following are the functions which are

used in batch processes.

Problem Recipe:

Figure 6.1: Recipe Chart

93$A'D/

6.2 MAIN FUNCTIONS TO AUTOMATE:

6.2.1 FILLING

It performs filling of the tank. The water entered in the machine is being added at the

water consumption. The main pump is off. We will control the pneumatic valve through

PLC when the valve is open water will start entering into the main vessel.

6.2.2 DRAINING

It performs the normal draining of the batch. The main drain valve is open during this

function. The function sets off the previous temperature control.

6.2.3 HEAT

It performs the normal heat-cool of the bath by the heat exchanger system. The desired

water temperature should be programmed for the water.

6.2.4 HOLD TIME

It performs to control various parameter for desired time.

6.2.5 STIRRING

This function performs to control speed of mixing by means of controlling frequency by

an inverter that is connected with motor.

93$A'D/

6.3 PROJECT DIAGRAMS:

6.3.1 BLOCK DIAGRAME:

Figure 6.2: Block Diagrame project 6.3.2 MODEL DIAGRAM:

Figure 6.3: Model Diagrame

93$A'D/

6.3.3 PROCESS FLOW CHART

='$=/)

6.4 IMPLEMENTATION OF FUNCTIONS:

6.4.1 start Filling The batch Tank

+%)/U&B/+

% ,/, % ) * ' + /%% % 1

&//'&),&//*%%

&%&,/,)//+/%%

+ /%%*6)//,)//++4B'/

%&&//+*

93$A'D/

CODE:

6.4.2 Heating

In heating function we increase the temperature of the tank up to the desired value by

means of heating device. The temperature sensor (Thermocouple) is used, its output

resistance is changed by sensing the temperature change, and the temperature transmitter

converts the temperature change into the current (4-20mA). The current is applied to the

PLC analog input (D110-D113), which accordingly generates the digital value. By the

compassion of digital value the PLC decide whether the heating device is on or off. we

have set two different temperature 30 c and 70 c. on reaching 30 c motor will start to

move. On 70c drain valve will be open.

The temperature output is given to PLC analog input which converts the analog value

into the digital and we will compare this digital value to the required temperature result is

true compare command will set M12 and motor at y0 will start to run.

93$A'D/

CODE:

6.4.3 Stirring

='&),/3&.)

//% '&(4 , & &)% , %

) &(4 %' (

)// & )//

%&&+4&&(4,'B

CODE:

93$A'D/

After reaching the temperature up to 30 c stirrer will start to move at 300 Hz

frequency.y0 out will remain on for 5 Minute y0 will reset.Stirrer will stop to move.

6.4.4 Drain

when temperature reaches to 70 c drain valve will open for 2 minutes.

Date post:	24-Nov-2015
Category:	Documents
Upload:	engrmishtiaq
View:	7 times
Download:	0 times

Chapters

Documents