Programmable Logic controller (PLC)

Abstract—This paper presents a technique to integrate a stand-alone weighing indicator with proprietary commands into a monitoring system of industrial production processes. The proposed technique is based on creating a new function block of the programmable logic controller (PLC) used in weighing machine control for converting weighing indicator commands into the Modbus-RTU commands. Creation of the function block operated in the PLC modeled CP1L-M30DR-D for converting commands of the AD-4401 weighing indicator to display on the Panel Master touch-screen monitor is described as an illustrative case study. Based on the proposed method, weighing data at the field site for local readout can be added into process data monitoring at the human machine interface (HMI) station of the PLC-based system. This enables ease of upgrading the weighing machine used, which has weighing indicator with local readout display. Performance of the proposed system integration is verified by experimental results.

Programmable logic controller or famously known as PLC is an electronic device used in automation of industrial process. A PLC obtains input data, processes it, and produces output data. Connected to sensors and actuators, PLCs are categorized by the number and type of inputs and outputs (I/O) ports they provide and by their I/O scan rate. Typically Reduced Instruction Set Computer (RISC) based and programmed in an International Electrotechnical Commission, IEC 61131 programming language. A PLC is designed for real-time use in rugged, industrial environments. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements and can withstand harsh condition such as:

Rubbish Collector Monitoring System using the Visual Basic to monitor the manual operation when automatic operation is problem or to do maintenance for the system. While PLC systems is one system to collect the rubbish or waste in the river and drain automatically. Main objective to design this project is to ensure the collecting process operation in consecutive condition. Rubbish Collector Monitoring System is control by Programmable Logic Controller (PLC) unit, Visual Basic (VB) for manual and this system will be installing together the project. To operate this project, ladder diagram will be design to assemble the process step. From ladder diagram, all sequence of the project step will be show. That is making easier to troubleshooting the problem. While Visual Basic will be create the command and built the form for control the system. The form divide into 3 part such as motor 1, motor 2 and motor 3 which represent for container and front net of rubbish collector.

Automated warehousing management information system using intelligent automation and information management, simplifying the materials and products operating processes and improve work efficiency. Complete automation in the storage management into the design and construction management, and monitoring level executives, performs layer 3 comprises a programmable logic controller (PLC)（see Figure 1）, are the PLC, the stacker storage means and PLC library institutions PLC, automated information system includes business leaders manage to line the entire staff class real-time automatic management until the business processes of all processed, providing full article information for staff, help employees master the goods dynamic information is accurate position, so that managers can be timely and accurate understanding of each storage management processes emerging issues and situations, timely fast processing, greatly improve the efficiency and reduce cargo damage worse. ERP system in the storage management application

PLCs were designed and developed by Modicon. A programmable logic controller (PLC) is a specialized computer used to control machines and processes. It therefore shares common terms with typical PCs like central processing unit (CPU), memory, software and communications. Unlike a personal computer, the PLC is designed to survive in a rugged industrial atmosphere and to be very flexible in how it interfaces with inputs and outputs of the real world. Programmable Logic Controller, or PLC for short, is simply a special computer control system that continuously monitors the state of input devices and make decisions based upon the custom program to control the state of output devices. PLC implements logic control functions by means of a program. PLC’S were designed to replace relay logic system. They are used in many industries such as oil refineries, manufacturing lines, conveyor systems and so on.

Programmable Logic Controller (PLC) is a microprocessor – based device that can be used to control movements of industrial systems such as electric motors, conveyors and robots [1] . PLC also defined as a specialized electronic device based on one or more microprocessors that are used to control industrial machinery or; a special – purpose industrial computer designed for use in the control of a wide variety of manufacturing machines and systems [2] while the National Electrical Manufacturing Association (NEMA) defines a PLC as a digital electronic apparatus with a programmable memory for storing instructions to implement specific functions, such as logic, sequencing, timing, counting and arithmetic to control machines and processes.

The use of the VFDs for the starting of the induction motor reduces the high inrush current, thus preventing the sag developing the distribution lines. The speed control is also easily achieved by using the VFD. Combining these drives with PLC control can result in great energy efficiency, which can in turn have impact o global warming. The technology advancement and availability of electric drives, the automation systems in manufacturing units are introduced with PLC.

3 METHODOLOGY 3.1 Introduction 14 3.2 Description of Design and Development Project 17 3.2.1 Drawing Plan 18 3.3 Software Development 3.3.1 CX-Programmer Tool 3.3.2 CX-Protocol Tool 3.3.3 NB- Series Programmable Terminal(PTs) 20 20 28 32 3.4 Hardware Development 38

There are countless equipments that belong to the framework of direct and indirect automation, where the PLC stands out. This equipment emerged in the 1960s, where by the end of the decade, according to [4], the controllers at that time were huge, taking up a lot of space, roughly equivalent to a cabinet, using electromechanical relays with several kilometers of wires. Especially when there was a need to change its mode of operation, a great job, because of the physical change of materials.

to the basic unit. However, some of the more sophisti- cated models can be linked by cable to expansion boards that can provide extra I/O. Therefore, with few excep- tions, when using this type of PLC, the system designer must take care to specify a unit that has enough inputs, outputs, and programming capability to handle both the present need of the system and any future modifications that may be required. Single board PLC’s are very inex- pensive, easy to program, small, and consume little po- wer, but, generally speaking, they do not have a large number of inputs and outputs, and have a somewhat lim- ited instruction set. They are best suited to small, rela- tively simple control applications [4].

Abstract—Eskom, the national electricity supplier of South Africa struggle to supply sufficient amount of power each year. This is partially due to residential consumers that use appliances that required significant amount of power. This results in transformers that overheat which decrease the efficiency of the transformer. Also due to the heat the life expectancy of the transformers decreases. A solution to this problem is to cool the transformer in a controlled manner. This paper therefore provides the design of a controlled cooling system for a three- phase power transformer that is energy efficient and displays the experimental results of this design. The cooling of the transformer make use of a thermoelectric cooling module (TECM) which is controlled by an programmable logic controller (PLC) which receives its data from a PT 100 thin sensors which is placed between the windings and core of the transformer. A prototype model of the actual transformer was used to perform the tests to indicate the cooling results. Solidworks® where used for the transformer simulation which were then implemented based on the results. A Flir thermal image camera was used to confirm the results and is compared to the simulated results. The payback period was determined to see how long the project will take before profit is made.

The aim of this project is to generate a controller device for FMS system. It consist of develop the programming for PLC that used to control the whole of FMS system which is assembly of back cover computer monitor. For this aim we should know of whole system stated FMS including of that FMS system, assembly of back cover monitor computer, PLC, pneumatic system, and the type of PLC we used. Below shown the element of the scope:

Energy crisis promotes the development of renewable energy, especially the solar energy. Sun tracking system proposed in this paper is such a device for efficiency improvement. This closed loop tracking system with two axis sun tracking method is controlled by a programmable logic controller (PLC) and is used for a large dish solar collector. A combination tracking mode combined active and passive tracking methods used in the design make the tracker efficient whatever the circumstances. Two stepper motors and two reduction boxes move the device towards the sun with chain transmission. Besides sun tracking, the system also has functions of overheat monitoring, wind speed monitoring and measurement of illumination.

2 The colour sensor senses the colouring box by using the Programmable Logic Controller (PLC) which acts as a main controller for the sorting system. The conveyor which is controlled by the PLC will bring the box that sensed by both Light Dependent Resistor (LDR) sensor and 4 super ultra brightness LED to the exact location. The circuit that consists of LDR sensor and super ultra brightness LED is able to determine the light intensity level on the box.

19 In this project, a distribution substation model is build for the DAS application. The distribution substation consists of the incoming, outgoing, and the load. The controller circuit of this substation is based on input and output of PLC. Moreover, a HMI will be constructed and interfaced with this substation so that its functions can be monitored and controlled from remote locations. Developments will be made so that the distribution substation will be able to perform the FLISR operation.

De-aerator temperature, Steam drum temperature, Under-bed boiler temperature, Turbine inlet steam temperature, Flue gas temperature.Wide area controlling and monitoring systems are essentially based on the SCADA system. In contrast to conventional control systems, where e.g. Programmable Logic Controller (PLC) system [4] is used for acquisition of data, Remote Terminal Units (RTU) [5,11] acquire digital and analog current, voltage and frequency measurements for SCADA system. RTUs are installed at selected locations of different grid stations to acquire complete analog and digital data of the station and are time-synchronized via Global Positioning System (GPS) [6] receivers with an accuracy of one microsecond. These RTUs are getting digital data from field instruments connected with relays to show and operate live status of Circuit breakers or isolators, however for analog data, transducers are connected with CT and PT. For power electric system, generating stations are producing electricity and distribute it on the network. Some electricity imported from other electric resources e.g. Independent Power Plants and electric companies etc.

processes of its activities, in which process automation has enabled industrial automation to make a major technological advance. In view of this, the paper aims to describe the importance of PLC in the industry in the automation process and its role during the fourth industrial revolution. Most industries are responsible for most of the percentage of GDP (Gross Domestic Product) movement in industrialized countries, at a time when companies seek to maximize their processes in an increasingly competitive market, always having to adapt any and all procedures with a view to technological advances, making a particular industrial process cleaner, which is of great importance to maintain the consumer market. The result is the benefits of using the PLC, decreasing hard work, repetitive work and jobs that brought major problems to employee health. Moreover, the implementation of the PLC has made this technology easily accepted by the job market, bringing optimization, increased productivity, generating more profits, making a highly profitable investment. Therefore, the PLC is responsible for the major technological breakthrough and will be part of industry 4.0.

PLC is a microprocessor-based control system, designed for automation processes in industrial environments. It uses a programmable memory for the internal storage of user- orientated instructions for implementing specific functions such as arithmetic, counting, logic, sequencing, and timing [6&7]. A PLC can be programmed to sense, activate and control industrial equipment, incorporates a number of I/O points, which allow electrical signals to be interfaced. Input devices and output devices of the process are connected to the PLC and the control program is entered into the PLC memory (Fig 1).

Projek Sarjana Muda ini adalah mengenai naiktaraf projek barisan pengeluaran berskala makmal. Penambahbaikan ini adalah penting untuk memastikan sstem yang asal dapat mencapai tujuannya sebagai alat untuk membantu proses pembelajaran pelajar kejuruteraan di universiti ini. Sistem ini sesuai digunakan untuk mendedahkan para pelajar kepada mekanisme asas yang terdapat pada barisan pengeluaran dan juga sistem kawalannya. Cabaran utama dalam pembangunan projek ini adalah untuk memasang semula penyambungan wayar sistem tersebut kepada Pengawal logik boleh aturcara (PLC) yang baru kerana PLC yang digunakan sebelum ini telah digunakan untuk projek yang lain. Dengan penambahbaikan ini, projek ini dapat menyumbang dalam pembangunan akademik di universiti ini. Sistem asal yang sedia ada mempunyai beberapa kelemahan mekanikal yang boleh menjejaskan operasi sistem ini, jadi beberapa penambahbaikan adalah perlu bagi memastikan sistem ini dapat beroperasi seperti yang dirancang. Keseluruhan sistem ini adalah berdasarkan barisan pengeluaran seperti yang terdapat di industri. Penggunaan PLC untuk mengawal sistem pneumatik ada digunakan di sesetengah industri. Automation Studio 5.0 digunakan untuk membuat simulasi bagi pengaturcaraan PLC. Pengaturcaraan dalam bentuk gambarajah tangga disimulasikan menggunakan Automation Studio 5.0 bagi memastikan pengaturcaraan tersebut boleh berfungsi. Penggunaan PLC menjadikan sistem ini sebagai sebuah sistem yang fleksibel serta boleh dinaiktaraf lagi. Oleh itu, projek ini mempunyai potensi untuk dipertingkatkan lagi untuk menjadi sistem pembuatan yang lebih kompleks.

Penggunaan alat dan bahan bantu mengajar ABBM banyak memberi sumbangan dalam meningkatkan pemahaman pelajar dan kualiti pengajaran dan pembelajaran dikalangan pelajar dan pendidik. Namun pelajar bermasalah dalam memahami konsep asas sesuatu pelajaran yang diajarkan. Kebiasaan juga para pendidik hanya menerangkan teori sahaja tanpa menunjukkan perkara sebenar kepada para pelajar. Berdasarkan pernyataan ini, satu kajian dibuat bagi mengkaji masalah kelemahan pelajar dalam memahami konsep asas kawalan magnet dan pengaturcaraan Programmable Logic Controller (PLC). Sebuah Kit Pengajaran Magnetik – PLC telah dibangunkan sebagai alat dan bahan bantu mengajar untuk membantu pelajar memahami dengan mendalam tentang kawalan motor elektrik dan PLC. Tujuan utama Kit Pengajaran Magnetik – PLC dibangunkan adalah untuk meningkatkan kefahaman pelajar terhadap konsep asas kawalan magnet dan pengaturcaraan PLC yang merupakan kelemahan pelajar yang dapat dikenalpasti melalui kajian keperluan yang telah dijalankan. Dua aspek penting yang diterapkan di dalam kit tersebut ialah pengetahuan konseptual (Conceptual Knowledge) iaitu pengetahuan teori dan pengalaman melalui pengalaman (Experiential Learning) iaitu pembelajaran melalui pengalaman. Fasa pembangunan produk ini adalah berdasarkan model rekabentuk ADDIE iaitu „analysis‟, „design‟, „development‟, „implementation‟ dan „evaluation‟. Lembaran kerja bagi ujikaji makmal juga telah dihasilkan bagi memudahkan pelajar memahami kawalan magnet, kawalan motor elektrik dan juga pengaturcaraan PLC. Kit Pengajaran Magnetik – PLC ini telah mendapat pengesahan pakar berkaitan kebolehgunaan, kebolehfungsian serta reka bentuk untuk tujuan proses pengajaran dan pembelajaran.