A MODEL OF TRAFFIC LIGHT SYSTEM BY THE
APPLICATION OF PLC
ZARIZAL BIN EDDY
UNIVERSITI TEKNIKAL MALAYSIA MELAKA (UTeM)
A MODEL OF TRAFFIC LIGHT SYSTEM BY THE
APPLICATION OF PLC
Thesis submitted in accordance with the partial requirements of the Universiti Teknikal Malaysia Melaka for the
Bachelor of Manufacturing Engineering (Robotics & Automation)
By
ZARIZAL BIN EDDY
B 050410157
UTeM Library (Pind.1/2007)
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PSM
JUDUL:A Model Of Traffic Light System By the Application Of PLC
SESI PENGAJIAN: Semester 2 2007/2008
Saya Zarizal Bin Eddy mengaku membenarkan laporan PSM / tesis (Sarjana/Doktor
Falsafah) ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
1. Laporan PSM / tesis adalah hak milik Universiti Teknikal Malaysia Melaka dan
penulis.
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis.
3. Perpustakaan dibenarkan membuat salinan laporan PSM / tesis ini sebagai bahan
pertukaran antara institusi pengajian tinggi.
4. *Sila tandakan (√)
SULIT
TERHAD
√ TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)
(TANDATANGAN PENULIS) Alamat Tetap:
No 54, Taman Permai, Bandar Ceneh Baru, 24000 Kemaman, Terengganu.
(TANDATANGAN PENYELIA)
Cop Rasmi:
FAKULTI KEJURUTERAAN PEMBUATAN
Rujukan Kami (Our Ref) : 20 September 2012
Rujukan Tuan (Your Ref):
Pustakawan
Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) Taman Tasik Utama, Hang Tuah Jaya,
Ayer Keroh, 75450, Melaka
Saudara,
PENGKELASAN LAPORAN PSM SEBAGAI SULIT/TERHAD
- LAPORAN PSM SARJANA MUDA KEJURUTERAAN PEMBUATAN (ROBOTIC AND AUTOMATION): ZARIZAL BIN EDDY
TAJUK: A MODEL OF TRAFFIC LIGHT SYSTEM BY THE APPLICATION OF PLC
Sukacita dimaklumkan bahawa tesis yang tersebut di atas bertajuk “A model of
traffic light system by the application of PLC” mohon dikelaskan sebagai
terhad untuk tempoh lima (5) tahun dari tarikh surat ini memandangkan ia mempunyai nilai dan potensi untuk dikomersialkan di masa hadapan.
Sekian dimaklumkan. Terima kasih.
“BERKHIDMAT UNTUK NEGARA KERANA ALLAH”
Yang benar,
………..
En. Ruzaidi bin Zamri Pensyarah,
Fakulti Kejuruteraan Pembuatan
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
Karung Berkunci 1200, Ayer Keroh, 75450 Melaka Tel : 06-233 2421, Faks : 06 233 2414
APPROVAL
This thesis submitted to the senate of UTeM and has been accepted as fulfillment of the requirement for the Bachelor of Manufacturing Engineering (Robotic and Automation).
The members of the supervisory committee are as follows:
………. (Mr. Ruzaidi bin Zamri)
Main supervisor
DECLARATION
I hereby, declare this thesis entitled “A Model Of Traffic Light System By The Application Of PLC” is the result of my own research except as cited in the
references.
Signature : ………
Author’s Name : Zarizal Bin Eddy
ABSTRACT
ii
ABSTRAK
DEDICATION
For my parents, my beloved late father Allahyarham Eddy Bin Lassim and my mother,
iv
ACKNOWLEDGEMENTS
The Name of Allah, The Most Gracious and Merciful.
TABLE OF CONTENT
Content List Page
Abstract i
Dedication iii
Acknowledgements iv
Table of Contents v
List of Figures ix
List of Tables xii
List of Abbreviations, Symbols, Specialized Nomenclature xiii
1. INTRODUCTION 1
1.1 Problem Statement 3
1.2 Aims/ objective 4
1.3 Scope 4
1.4 Significant of Study 4
1.5 Conclusion 5
2. LITERATURES REVIEW 6
2.0 Introductions 6
2.1 Programmable Logic Control (PLC) 7
2.1.1 Introduction 7
2.1.2 Features 8
2.1.3 Recent project using PLC 10
2.2 Traffic Light 11
2.2.1 Introduction 11
2.2.2 Features 12
vi
2.3 Recent Project 15
2.3.1 Intelligent Traffic Lights Control by Fuzzy Logic 15
2.3.2 Majlis Perbandaran Kota Baru 16
2.3.3 Control of vehicular traffic through a sequence of traffic lights positioned with disordered interval 19
2.3.4 An urban traffic network model via coloured time Petri net 19
2.4 Conclusion 20
3. METHODOLOGY 21
3.0 Introduction 21
3.1 Programming approach 22
3.2 Development Phase 23
3.2.1 Gantt Chart 23
3.2.2 Project flow description 25
3.2.3 Flow Chart 26
3.3 Equipment Being Selected 28
3.3.1 Control system 28
3.3.1.1 Keyence PLC 28
3.3.1.2 Software 30
3.3.2 Electrical component 32
3.3.2.1 Power Supply (AC to DC) 32
3.3.2.2 Plug 32
3.3.2.3 Wire 33
3.3.2.4 Maintained push button switch 34
3.3.2.5 Emergency pushbutton switches 35
3.3.2.6 Light indicator 36
3.3.2.7 Terminal block 37
3.3.3.1 Din rail 38
3.3.3.2 Screw 38
3.3.3.3 Acrylic 39
3.4 Technique 40
3.4.1 Base construction 40
3.4.2 Wiring 42
3.4.3 Programming 43
3.5 Tool 45
3.5.1 Jig saw 45
3.5.2 Hand drill 46
3.5.3 Hole saws 47
3.5.3 Super glue 47
3.6 PLC compared with other control systems 48
3.7 Conclusion 49
4. RESULT 50
4.0 Introduction 50
4.1 Mechanical construction 52
4.1.1 Base 52
4.1.2 Traffic light 54
4.2 Electrical 55
4.2.1 PLC Communication Cable 55
4.2.2 Wiring 57
4.2.3 Wire marking 62
viii
4.3.1 List of input/output 63
4.3.2 Timing Chart 64
4.3.4 Programming 66
4.3.4.1 PLC 1 66
4.3.4.1 PLC 2 67
4.3.4.1 PLC 3 69
4.4 Conclusion 70
5. DISCUSSION 71
5.0 Introduction 71
5.1 Problem encounter 72
5.1.1 Programming 72
5.1.2 PLC wiring 75
5.1.3 Design for programming 76
5.2 Finding 78
5.2.1 Keyence PLC KV series 78
5.2.2 Timing chart 78
5.2.3 Process sequence 78
5.3 Conclusion 80
6. CONCLUSION 81
6.0 Conclusion 81
6.1 Recommendation and future work 81
APPENDICES 84
A Drawing base for laser cutting process
B Timing chart
C Ladder diagram for PLC 1
D Ladder diagram for PLC 2
x
LIST OF FIGURE
Content List Page
2.1 The first signal tower with automatic lights, at Michigan and Woodward 11
2.2 Traffic light model 13
2.3 A general structure of the fuzzy traffic light control system 15
2.4 Induction loop traffic sensors 16
2.5 The traffic light that uses the sensor 17
2.6 Main Switch Board and Controller System 17
2.7 PLC Controller System 18
2.8 Metal Detector Sensor under the Road Pavement 18
3.1(a) Flow chart of overall flow process for PSM 1 26
3.1(b) Flow chart of overall flow process for PSM 2 27
3.2 Keyence PLC 28
3.3 LBK software 30
3.4 KV builder ladder 30
3.5 Power supply 32
3.6 Plug 32
3.7 Wire 33
3.8 Start button 34
3.9 Emergency stop button 35
3.10 Light indicator 36
3.11 Terminal block 37
3.12 Din rail 38
3.13 Screw 38
3.14 Acrylic 38
3.15 Main acrylic board 40
3.17 Join between top and edge 41
3.18 Wire markers 42
3.19 Jig saw 45
3.20 Hand drill 46
3.21 Hole saws 47
3.22 Super glue 47
4.1 Complete model 50
4.2 Complete model with device name 51
4.3 Base 52
4.4 Laser cutting process 52
4.5 Traffic light assembly 54
4.6 Light indicator mount to traffic light 54
4.7 Wire positions 55
4.8 Soldering process 55
4.9 PLC communication cable 56
4.10 Electrical circuit for PLC 1 57
4.11 Electrical circuit for PLC 2 58
4.12 Electrical circuit for PLC 3 58
4.13 Wiring below the model system 59
4.14 Wiring for PLC and terminal block 60
4.15 Wiring in traffic light box 60
4.16 Wire marking 62
4.17 Timing chart 64
4.18 Ladder diagram for PLC 1 66
4.19(a) Ladder diagram for PLC 2 67
4.19(b) Ladder diagram for PLC 2 68
4.20(a) Ladder diagram for PLC 3 69
xii
5.1 Keyence KV series 72
5.2 Help instruction 73
5.3 Setting for timer 73
5.4 Ladder diagram 74
5.5 Wiring for input and output 75
5.6 Connection for PLC to combine in one system 76
5.7 Three PLC being use 77
LIST OF TABLE
Content List Page
3.1 Gantt chart for PSM 1 23
3.2 Gantt chart for PSM 2 24
3.3 Keyence PLC product description 29
xiv
LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED
NOMENCLATURE
PLC - Programmable Logic Control
NEMA - National Electrical Manufacturer Association SCADA - Supervisory Control and Data Acquisition
ATC - Advanced transportation controller
PID - Proportional integral controller
DCS - Distributed control system
I/O - Input and output
LED - Light emitting diode
HSS - High Speed Steel
nm - Nanometer
mm - millimeter
φ - Diameter
DC - Direct current
AC - Alternating current
V - Volt
A - Ampere
NO - Normally open
NC - Normally closed
“ - Inch
CHAPTER 1
INTRODUCTION
1.0 Introduction
Traffic light which is one of the vital public facilities plays an important role to the road users. It will help to curb from accidents and gridlocks. This research exposed the operational of traffic light such as understanding the flow of the traffic system and the program itself. Traffic signal light is used to control the movement of vehicles and passengers, so that traffic can flow smoothly and safely. Traffic signal lights have been around for years and are used to efficiently control traffic through intersections. Although traffic signal lights are relatively simple and commonplace, they are critical for ensuring the safety of the driving area. The growing use of traffic lights attests to their effectiveness in directing traffic flow, reducing the number of accidents, and the most recently to their utility in controlling the flow of traffic through metropolitan areas when have been used together with computer systems.
2
1.2 Problem Statement
4
1.3 Aims/ Objective
The objective of this project is:
• To develop and design a traffic light system using PLC.
• Create prototype for traffic light model
• Develop ladder diagram using Keyence PLC
1.4 Scope
The scope of this project will be cover on the design and programming of a crossroad traffic light system. The design work will include the application of Solid work and Autocad software. On the programming part, programmable logic controller will be used to integrated with the hardware or model that will be develop.
1.5 Significant of Study
Traffic light is the common use in our journey. Experience and knowledge is required to explore this system. This project is the combination of three main enginerring field which is mechanical, electric and electronic and computer programming. The usage of PLC in this project give an exposure on how to automate the system.
In construction the ladder diagram, creativity and innovativity are need to make a design although in creating design prototype. All the consideration must be count to complete this project. This system will be act as the countermeasure of traffic jammed at junction.
