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    Efficient Automation of Concrete Batching Plant Using PLC & Scada Project Reference No: 38S0193

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    Gangadhar Pradhan
    This document describes a project to automate a concrete batching plant using a PLC and SCADA system. The plant includes aggregate bins, a traveling weighing bucket, motorized gates, a mixer, and other components. Previously, concrete mixing was done manually, but automation allows mixing in precise proportions much faster. The project objectives are to gain experience with automation technologies like PLCs, sensors, and SCADA. A methodology is outlined involving design, fabrication, electrical integration, testing and documentation. A SCADA screen is developed to monitor and control the process. Automation provides benefits like increased production, consistent quality, and reduced labor requirements.

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    Efficient Automation of Concrete Batching Plant Using PLC & Scada Project Reference No: 38S0193

    Uploaded by

    Gangadhar Pradhan
    117 views4 pages
    This document describes a project to automate a concrete batching plant using a PLC and SCADA system. The plant includes aggregate bins, a traveling weighing bucket, motorized gates, a mixer, and other components. Previously, concrete mixing was done manually, but automation allows mixing in precise proportions much faster. The project objectives are to gain experience with automation technologies like PLCs, sensors, and SCADA. A methodology is outlined involving design, fabrication, electrical integration, testing and documentation. A SCADA screen is developed to monitor and control the process. Automation provides benefits like increased production, consistent quality, and reduced labor requirements.

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    This document describes a project to automate a concrete batching plant using a PLC and SCADA system. The plant includes aggregate bins, a traveling weighing bucket, motorized gates, a mixer, and other components. Previously, concrete mixing was done manually, but automation allows mixing in precise proportions much faster. The project objectives are to gain experience with automation technologies like PLCs, sensors, and SCADA. A methodology is outlined involving design, fabrication, electrical integration, testing and documentation. A SCADA screen is developed to monitor and control the process. Automation provides benefits like increased production, consistent quality, and reduced labor requirements.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    117 views4 pages

    Efficient Automation of Concrete Batching Plant Using PLC & Scada Project Reference No: 38S0193

    Uploaded by

    Gangadhar Pradhan
    This document describes a project to automate a concrete batching plant using a PLC and SCADA system. The plant includes aggregate bins, a traveling weighing bucket, motorized gates, a mixer, and other components. Previously, concrete mixing was done manually, but automation allows mixing in precise proportions much faster. The project objectives are to gain experience with automation technologies like PLCs, sensors, and SCADA. A methodology is outlined involving design, fabrication, electrical integration, testing and documentation. A SCADA screen is developed to monitor and control the process. Automation provides benefits like increased production, consistent quality, and reduced labor requirements.

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    © All Rights Reserved
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    of 4

    EFFICIENT AUTOMATION OF CONCRETE BATCHING PLANT

    USING PLC & SCADA


    PROJECT REFERENCE NO: 38S0193
    COLLEGE : ACS COLLEGE OF ENGINEERING, BENGALURU
    BRANCH : ELECTRICAL & ELECTRONICS ENGINEERING
    GUIDE : MRS. JAYASHREE K R
    STUDENTS : MR. VINAYKUMAR.A
    MR. SRIHARI YG
    MS. SHREELAKSHMI S G
    MS. DEEPA M A
    Keywords
    PLC, SCADA, Proximity Sensors, Travelling bucket, Concrete mixing
    INTRODUCTION
    The advance in electronics and computer technology has resulted in enormous impact on various industrial
    manufacturing practices. One such application in cement industry is concrete mixing.
    The traditional process used earlier for the concrete mixing, where workers used to carry the aggregate and
    mix manually. But sometimes the mixing proportions may not be up to the mark also it takes time to mix
    manually.
    In the process of concrete mixing, an aggregate consists of gravel, sand and cement which are stored in a 4
    bin arrangement, a weighing bucket will travel below this bin arrangements and collect the material from above
    bins. Each bin will have a motorized gate which will open and close the bin gate sequentially.
    The purpose of this project is to automate the entire concrete batching operation and control, using PLC
    (Programmable Logic Controller) and SCADA (Supervisory Control and Data Acquisition) system, so that
    manual problems can be solved to a greater extent. In a fully automated system this operation can be completed
    within a few seconds which shows the time efficient and also the ingredients are weighed with help of load cell
    used and mixed in a given proportion automatically.

    Objectives
    This is a designed project for Industrial specification.
    The objective of the project is to teach students the automation technology.
    Here the students get exposure to
    I. Automation Products:
    1. The students will get hands on experience on using PLC, SCADA, Proximity sensors, Load cell, DC
    drives etc.
    2. The students will also get exposure on the mechanical design of a weighing bin, Belt
    Conveyors, Skip hoist or bucket elevator, winch system, screw conveyors, etc.
    II. System Integration:
    On the system integration side, the students will be learning the wiring practices used in the industry likes,
    Lugs, ferruling, terminals, etc. and also they will be developing the PLC program to make the above machinery
    work automatically without the need of any manpower. They also develop SCADA screen in the computer for
    this application. They develop mimic diagrams, report generation and logging function in the SCADA
    Methodology
    Methodology used will be as follows.
    1) First step is to develop AutoCAD drawings for the mechanical manufacturing. The individual components
    and the assemble drawings to be developed. The components are weighing bins, travelling weigh hopper,
    motorized gates for opening and closing of the bins, the skip bucket, model of mixer, cement silo, cement screw
    conveyor, weigh hopper for cement, water and chemical additive. Mixer discharge door
    2) Once the drawing is vetted by our machine builder/ mechanical designer, implement the changes in to the
    drawing
    3) fabricated the equipment, welding, grinding, powder coating etc
    4) Integration of mechanical equipment with electrical system
    5) Final trials and testing, demonstration, documentation
    In this project, an automation scheme for the above process has been implemented using programmable logic
    controller (PLC) and Supervisory Control and Data Acquisition (SCADA) system. The PLC implementation
    has been carried out using Versa Max PLC, while the SCADA system has been implemented using Cimplicity
    software

    Final assembly drawing(drawing-1)


    Results
    The SCADA screen in this project does a lot of things like MIMIC screens, alarm generations, logging
    into the data base and report generation. However in view of the vastness of the work, the scope of this project
    is limited to creating and executing MIMIC screens.
    SCADA SCREEN
    The above icon shows the aggregate weighing part of the batching plant. The operator can use UP/Down
    keys in each smaller display to set the desired weights of each ingredient. The larger display shows the value of
    each ingredient in a batch. The ladder program in the PLC separates in individual weights from the cumulative
    weights. The green lights lit up to indicate which bin is at present open, for the purpose of weighing. This is
    actually a maintenance tool. This helps the maintenance engineer to trouble shoot any wiring problem during
    running. The Icons shows the opening of the gate and falling of the material. This icons appears only if the gate
    in operation.
    CONCLUSION
    1. Fully automated plant of this type is very beneficial for society. If this were to be a manual plant there
    would be a need of at least 100 workers to carry out these concrete mixing for large mixing purpose.
    During the manual operation, the mixing may not be properly done and hence the quality of the product
    will be poor.
    2. Automation not only speeds up the process by over 50% but also gives the same quality all the time and
    also increases the production by 60%. Automation needs only 2 to 3 operators and that too when there is
    a need. Otherwise everything is automated and runs on its own. Hence the total time required is
    substantially reduced.
    3. In a fully automated system, one complete concrete mixing operation is done in every 25 seconds and no
    workers needed. In a large machine tons of mixing can be done in a day continuously.
    FUTURE SCOPE OF WORK
    The future scopes of work in this plant are,
    1. The water weighing system can be incorporated by using load cells and hoppers which improves the
    quality of the concrete mix. Further there will be scope to add chemical called “Add mixture” which
    further enhances the quality of the mix by improving its strength.
    2. NON contact measurement of moisture in the mixer using ultra sound technique can be adopted with the
    help of PLC and sensors. This helps in adding the appropriate amount of water irrespective of the
    weather condition and the wetness of the sand
    3. Soft starters can be adopted for starting of the mixer instead of fluid coupling which is presently being
    used.
    4. Periodic Report generating system can be incorporated, which gives information about the usage of
    materials .Additional limit switches can also be adopted for providing safety to the equipment for
    emergency conditions .

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