Monitoring and Controlling of Industrial Crane using
Transcription
Monitoring and Controlling of Industrial Crane using
5|Pag e Australian Journal of Information Technology and Communication Volume II Issue I ISSN 2203-2843 Monitoring and Controlling of Industrial Crane using Programmable Logic Controllers Harpreet Singh Bedi* Krishan Arora**Rk Sharma*** [email protected] ABSTRACT In this paper, we will work on Programmable logic Controllers Changed and control sequences had to be modified. PLC is a to control the operation of an Industrial Crane and many other small computer which is used for Automation and Applications which is used in the industry. Earlier in Industry, applications of Real -World Process, Such as a control of We used certain control devices which were controlled and Machinery on assembly lines, Timers and Counter wired directly with the system that leads to certain irregularity applications and other applications used the help of PLC. It in the functioning of the whole system. To overcome the is usually a Microprocessor. The Program which is to be in-functionality of the system which was caused by large written in ladder programming can use control complex number of wires, We came cross towards Programmable logic sequencing and is written with the help of software. The controllers (PLC).Earlier Human controls the crane & that Program in Plc can be stored in battery backup memory. passes through large drawbacks such as more numbers of Unlike other equipment’s General purpose computers, the wires required, large faults will be there and many more plc is well designed and manufactured for extended difficulties in troubleshooting & repair work .Due to these temperature ranges, immunity to noise, and is mechanically Drawbacks the production suffers a lot and hence growth more rugged and resistant to vibration and impact. By decreases rapidly. This is the main reason in order to remove implementing this project we will decreases the man power, irregularity of relays and wiring issue we prefer PLC to hence will increase in production of the industry [4]. control and monitor the operation of crane in the industry. II. DEFINITION OF PLC Keywords – PLC, HMI, automatic control, Hardware configuration (crane model) PLC is a Digital Electronic Device that uses a Programmable memory to store instruction and to I. INTRODUCTION implement function such as Timing, Counting, Logic, Sequencing and arithmetic in order to control the machines PLC’s were developed in the late 1960’s to eliminate the and their processes. Input Devices such as switches, large cost involved in changing complicated relay based different types of sensors are used to control the input machine control systems. These relay based systems were switching and output devices such as motors solenoids are very flexible; their configuration and capability and used to control the output circuitry. Input devices e.g. structure or complete replacement of relay based system was switches, and output devices e.g. motors, being monitored necessary every time when the production requirements and controlled are connected to the PLC and then the controller monitors the inputs and outputs according t this program stored in the PLC by the operator and so controls the machine or process[3]. 6|Pag e Australian Journal of Information Technology and Communication Volume II Issue I ISSN 2203-2843 Basically PLC was designed as a replacement for hard wired programmable controller, consists of two basic sections: the delay and other timer, counters and logic Functions. PLCs central processing unit and the input/output interface have certain advantages that make it possible to modify a system. control system without having to rewrite the connections to the input and output devices. The basic difference is that the developer uses different set of mnemonics for different set of instructions. Thus making it a more flexible system which can be used to operate, monitor and control the variety of different systems. Figure 2:-PLC CPU Architecture The operation of a programmable controller is relatively simple. The input and output system is attached to the devices that will help the plc to run and execute various input and output functions. The input and output devices an Figure 1:-PLC Architecture be either analog or digital in nature which can be limit Switches, pressure transducers, push buttons, motor starters, I. PLC OPERATION solenoids, etc. The input/output module makes the connection between CPU and between input and outputs and A PLC works by continually scanning a program. A PLC to the concerned devices. program is generally executed repeatedly as long as the controlled system is running. [1]. the status of physical input In the working Phase, CPU has to undergo three Process i.e. points is copied to an area of memory accessible to the it reads the data from the input devices, it executes, or processor, sometimes called the "I/O Process table". The performs, the control program stored in the memory system program is designed to work from the first input to the last And it controls and updates the output. The process of input in a rung. reading the input, performing and executing the functions in Then the processor takes some time to interpret and evaluate the memory, and updating the results and outputs is known all the input of the rungs and then update the I/O image table as scanning. with the status of the outputs. This scan time may be a few milliseconds for a small program or on a larger and speedy The input/output system forms the interface by which field processor and slow processor could take much longer (say, devices are connected to the controller .The main purpose of up to 100 ms) to run the program. If the processor takes too the interface is to condition the various signals received much in executing the instruction the plc response to the from or sent to external field devices. Incoming signals from processor will decrease. There are typically more than 3 but sensors (e.g., push buttons, different types of switches) are we can focus on the important parts and not worry about the the devices which are used at input terminals. The output others. Typically the others are checking the system and Devices that can be started or functional like the output updating the current internal counter and timer values [6].A devices are connected at the output terminals of the output 7|Pag e Australian Journal of Information Technology and Communication Volume II Issue I ISSN 2203-2843 interface [2]. The system power supply provides all the voltages required for the proper operation of the various central processing unit sections. Figure 3:-PLC Scanning III. Hardware Design for the Model Figure 4:- Experimental setup V. PROPOSED WORK In this paper, we first developed the ladder logic to control the cranes in a particular direction, and then simulate the ladder programming using Rs Logix Software for PLC. Then design and assembled the crane model by selecting various types of motors then checked the testing of relay module and monitoring the voltage current and temperature of the drives in the present scenario. Thus our proposed work is mainly based on Rs Logix software. Let’s compare a simple ladder diagram with its real world external physically connected relay circuit and see the differences. 8|Pag e Australian Journal of Information Technology and Communication Volume II Issue I ISSN 2203-2843 3. They are easily programmed and have easily understood programming language. 4. It contains programmable functions. 5. It scans memory, inputs and outputs in predetermined manner. 6. It provides error checking diagnostics. 7. A PLC can provide some form of monitoring capabilities 8. A PLC can be effectively designed for a wide variety of control tasks. Figure 5:-Relay Circuit VIIII. CONCLUSION:In the above circuit, the coil will be energized when there is a closed loop between the + and - terminals of the battery. The same circuit can be made with the help of a ladder diagram A ladder consists of individual rungs which contains one or more inputs connected to it and one output. The first step on a rung is to check the input instruction and last will be always the (or its equivalent). Figure 6:-Ladder Diagram Notice in this simple one rung ladder diagram we have recreated the external circuit above with a ladder diagram. In this Circuit we used two switches SW1 and SW2, for loading the instructions. At the end of the rung there will be a output Coil. Different manufacturers use different output instructions for executing the outputs. Different PLCs also require an end instruction on the rung after the end rung [5]. V1. PRESENT THEORIES & PRACTICES Originally they were designed as a replacement for hard-wired relay and timer logic control systems. PLCs have the great advantage that it is possible to modify a control system without having to rewrite the connections to the input and output devices, The Program in Plc can be stored in battery backup memory only. Unlike other equipment’s General purpose computers, the plc is well designed and manufactured for extended temperature ranges, immunity to noise, and is mechanically more rugged and resistant to vibration and impact. By implementing this project we will decreases the man power, hence will increase in production of the industry [4]. PLCs can be compared to computers/Pc but have more advantages and functions as compared to the controllers 1. PLC is more immune to noise vibrations temperature and lusty condition. 2. The interfacing for inputs and outputs is the controller. The plc is well designed and manufactured for extended temperature ranges, immunity to noise, and is mechanically more rugged and resistant to vibration and impact. If it want a device in a PLC system to behave differently or to control a different process element, all have to do is change the control Program Earlier Human controls the crane & that passes through large drawbacks such as more numbers of wires required, large faults will be there and many more difficulties in troubleshooting & repair work .Due to these Drawbacks the production suffers a lot and hence growth decreases rapidly. This is the main reason in order to remove irregularity of relays and wiring issue we prefer PLC to control and monitor the operation of crane in the industry. In future definitely PLC is dominated on all other controlling methods. References: [1 ] .Mohammed Bani Younis and Georg Frey.” A Formal Method Based Re-Implementation Concept for PLC Programs and Its Application”. 1-4244-0681-1/06/2006 IEEE. [2]. Vijay Kumar Khatri, Ahsan Javed Ghangro, Jetandar Kumar and Syed Jaad UI Haque.,”Industrial Data Acquisition and Control System using two PLCs’ Networked over MPI Network”, 2009 IEEE symposium on Industrial Electronics and Application (ISIEA2009). [3]. S. Da'na, A. Sagahyroon , A. Elrayes, A.R. Al-Ali, R. Al-Aydi, “Development of a monitoring and control platform for PLC-based applications”, Computer Standards & Interfaces 30 (2008) 157–166. 4]. YU Huiqun., “The Design and Realization of PID Liquid Level Control System”,Based on S7-200 and EM235, 2010 International Conference on Intelligent Computation Technology and Automation,978-0769540771/10$26.00©2010IEEEDOI10.1109/I CICTA.2010.800 [5]. Liu Le, Wang Changsong, Wang Xingbing, “The research of the free mode communication between Siemens S7 -200 PLC and PC,” Mechanical Engineering&Automation, no.04, pp. 22 – 24. [6]. Mohamed Endi.,Y.Z.Elhalwagy.,Attalla hashad.,“Three-Layer PLC/SCADA System Architecture in Process Automation and Data Monitoring” 978-1-4244-5586-7/10/C 2010 IEEE.