Minor Project Report
Minor Project Report
Minor Project Report
1. INTRODUCTION ................................................................................................. 3
1.2.1 Sequential:................................................................................................ 4
2 SYSTEM HARDWARE........................................................................................ 8
4.1.7 AMMETER............................................................................................ 24
4.1.8 MCB....................................................................................................... 25
Clearly the likelihood of arc flash incident is high when employees are working on
or near exposed live parts. Live parts are considered to be exposed when they are
not suitably guarded, isolated, or insulated. Normal operation of enclosed
equipment is not likely to result in an arc flash provided it is in a normal operating
condition. So how do we define normal operating condition? A great start is found
in the Standard for Electrical Safety in the Workplace, NFPA 70E. Here you will
find that to be in normal operating condition, the equipment must:
be properly installed.
be properly maintained.
used in accordance with instructions included in the listing and labelling and in
accordance with manufacturer’s instructions.
Sequential
Dual
Forward Reverse
Star Delta
1.2.1 Sequential:
1.2.2 Dual:
In dual mode of operation as the name suggest two equipments or led are turned ON
or OFF simultaneously This is carried out using plc logic and hence performed on
the board.
This can also be understood by the concept of electric motor.During starting the
motor windings are connected in star configuration and this reduces the voltage
across each winding 3. This also reduces the torque by a factor of three. After a
period of time the winding are reconfigured as delta and the motor runs normally.
The CPU itself can be located on a card which is pluggable into a dedicated slot on
the backplane of the PLC. The particular processor employed in a PLC together
with the particular choice of input and output cards installed in the PLC rack are
often referred to as the hardware configuration of the programmable logic
controller. The hardware configuration also includes the particular addresses which
the I/O cards. Each option module typically has a plurality of input/output points.
The option modules are coupled through an interface bus, for example via a
backplane, to a main controller having a microprocessor executing a user program.
Option modules may also include a microprocessor and a memory containing
separate user programs and data directed to a particular operation of the PLC
system. During the execution of a stored control program, the PLC's read inputs
from the controlled process and, per the logic of the control program, provide
outputs to the controlled process. The outputs typically provide analog or binary
voltages or "contacts" implemented by solid state switching devices.
In many industries, airports etc. the multiple use of electrical machine is expected to
maintain an ease in process and communication. It demands machines and electrical
in particular to carry more than one operation at a time. Using only hardware may
increase in the manual process for industry or company therefore software part is
also essential to carry these multiple processes. Therefore using both hardware and
software develop a system which create suitable environment for use of multiple
operations.
2.1 Introduction
The hardware part of this project is Programmable logic controller (PLC) and a
traffic light model. RX-LOGIX 5000 is the type of PLC used in this project as the
processor to control the traffic light. This type of PLC was been chosen because the
characteristic is fully necessary by the development of traffic light system.
The four ways traffic light model is constructed to display how this traffic light
control system is running. This traffic light model has a complete set of traffic light
signal which are red, yellow and green as a traffic signal for each lane. Each lane
also has two limit switches represent as a sensor on the road. The first sensor placed
in front of the lane to detect the presence of a car at the junction and the second
sensor placed at certain length from first sensor to determine the volume of car at
that lane. The right connection between PLC and traffic light model is very
important because it can avoid the problem or conflict when the program is
transferred to PLC.
Many PLC configurations are available, even from a single vendor. But each of
these has common components and concepts. The most essential component is
are:
1. Power supply – This can be built into the PLC or be an external unit.
2. Common voltage levels required by the PLC are 24Vdc 120Vac 220Vac.
5. Indicator lights – These indicate the status of the PLC including power on,
program running, and a fault. These are essential when diagnosing
problems.
7. Mini: These are similar in function to PLC racks, but about the half size.
Dedicated Backplanes can be used to support the cards OR DIN rail
mountable with incorporated I/O bus in module.
9. Micro: These units can be as small as a deck of cards. They tend to have
fixed quantities of I/O and limited abilities, but costs will be lowest. DIN rail
mountable
The basic PLC schema include CPU, power supply, memory, Input block, output
block, communication and expansion connections. Figure shows the PLC system
overview.
CPU modules - The Central Processing Unit (CPU) Module is the brain of the
PLC.Primary role to read inputs, execute the control program, update outputs. The
CPU consists of the arithmetic logic unit (ALU), timing/control circuitry,
accumulator, scratch pad memory, program counter, address stack and instruction
register. A PLC works by continually scanning a program.
6. FLASH Memory
7. Compact Flash – Can store complete program information, read & write text
8. files
9. I/O Modules - Input and output (I/O) modules connect the PLC to sensors and
actuators. Provide isolation for the low-voltage, low-current signals that the
PLC uses internally from the higher-power electrical circuits required by most
sensors and actuators. Wide range of I/O modules available including:
10. digital (logical) I/O modules and analogue (continuous) I/O modules.
CHECK INPUT STATUS-First the PLC takes a look at each input to determine
whether it is on or off condition.
EXECUTE PROGRAM-Next the PLC executes a program by one instruction at a
time. If the first input is on then it should turn on the first output. Since it already
knows then it will be able to decide whether the first output should be turned on
UPDATE OUTPUT STATUS-Finally the PLC updates the status of the outputs. It
updates the outputs based on which inputs are on during the first step and the results
of executing your program during the second step. Based on the example in step 2 it
would now turn “ON” the first output because the first input is “ON” and your
program said to turn “ON” the first output when this condition is true.
DATA STORAGE -Typically there are registers assigned to simply store data. They
are usually used as temporary storage for math or data manipulation.
They can also typically be used to store data when power is removed from the PLC.
PLC RX-LOGIX5000 configuration. The main body of this PLC is power supply
unit, Central processor unit and input/output slot. The power supply unit receive the
required PLC voltage is 240Vac. For safety the voltage to PLC must connect to
automatic circuit breaker before connect to the PLC because to protect the PLC
from overload. The CPU covered by Analog input/output slot, RS232 port, and
processor. The inputs/outputs slot uses for system are using digital input and digital
output. There are not limited slot for input and output port and can use for multiple
inputs/outputs card.
Once hardware is designed ladder diagrams are constructed to document the wiring.
For this project, existed PLC cabinet box are use and connect with the traffic light
model. A basic wiring diagram is as shown in figure. The PLC would be supplied
with AC power 240V and then I/O card supplied with DC power 12V to 24V. The
common for input card is 24Vdc and for output card is 0Vdc. A fuse is used after
disconnect to limit the maximum current drawn by the system.
The PLC input wiring address start with number 0.00 to 0.15 for every input card.
When the other input card is install to the PLC socket the address for this input card
will start with number 1.00 to 1.15 and so on. Figure shows the wiring diagram for
input card which this input card connects to sensor (limit switch) at traffic light
model.
The diagram workspace can display a ladder program, the symbol table of that
program or the Mnemonic view. The details displayed depend upon the selection
made in the project workspace.
When a new project is created or a new PLC added to a project, an empty ladder is
automatically displayed on the right-hand side to the project workspace. The symbol
table and Mnemonics view must be explicitly selected to be displayed. All views
can be opened at the same time and can selected via option associated with the
window menu.
Before construct a ladder logic diagram, program flowchart is ideal for a process
that has sequential process steps. The steps will be executed in a simple order that
may change as the result of some simple decisions. The block symbol is connected
using arrow to indicate the sequence of the steps and different types of program
actions. The other functions may be used but are not necessary for most PLC
applications.
first of all we take the plywood of about 4*3 feet for making the base. for making
the base portable we can cut it into 2 pieces about 2*1.25.to place it in balanced
condition we can make a balancing wood for this we have to take a piece of wood
about 3*2 Inch and connect this cutted wood in the edge of the ply.rub the edges of
the ply through the sand paper to make it smooth
A pilot light or indicator light from Grainger is designed to signal when a machine’s
process has started or ended. Mounted in an instrument panel, on machinery or in a
control room, the indicator light is a necessary safety measure in the manufacturing
facility, lab or chemical plant. Find pilot light options here in a variety of sizes and
voltage ratings and in assorted colors, including red and green.
Fig multimeter
4.1.4 RELAY
4.1.5 CONTACTOR
fig. Contactor
Contactors come in many forms with varying capacities and features. Unlike
a circuit breaker, a contactor is not intended to interrupt a short circuit current.
Contactors range from those having a breaking current of several amperes to
thousands of amperes and 24 V DC to many kilovolts. The physical size of
contactors ranges from a device small enough to pick up with one hand, to large
devices approximately a meter (yard) on a side.
A contactor has three components. The contacts are the current-carrying part of the
contactor. This includes power contacts, auxiliary contacts, and contact springs.
4.1.6 VOLTMETER
fig Voltmeter
The instrument which measures the voltage or potential difference in volts is known
as the voltmeter. It works on the principle that the torque is generated by the current
which induces because of measurand voltage and this torque deflects the pointer of
The voltmeter constructs in such a manner that their internal resistance always
remains high. If it connects in series with the circuit, it minimises the current which
flows because of the measurand voltage. Thus, disturb the reading of the voltmeter.
The voltmeter always connects in parallel with the circuit so that the same voltage
drop occurs across it. The high resistance of the voltmeter combines with the
impedance of the element across which it is connected. And the overall impedance
of the system is equal to the impedance that the element had. Thus, no obstruction
occurs in the circuit because of the voltmeter, and the meter gives the correct
reading.
4.1.7 AMMETER
FIG Ammeter
The principle of ammeter is that it must have a very low resistance and also
inductive reactance. Now, why do we need this? Can’t we connect an ammeter in
parallel? The answer to this question is that it has very low impedance because it
must have very low amount of voltage drop across it and must be connected in
series connection because current is same in the series circuit.
4.1.8 MCB
FIG. MCB
Nowadays we use more commonly miniature circuit breaker or MCB in low voltage
electrical network instead of fuse.
Normally Open Type Push Button is used in project for START operation
and for selection of MODE operation
Normally Closed Type Push Button is used for executing STOP operation.
A Normally Open (NO) Push Button is a push button that, in its default state, makes
no electrical contact with the circuit. Only when the button is pressed down does it
make electrical contact with the circuit.
A Normally Closed (NC) Push Button is a push button that, in its default state, makes
electrical contact with the circuit.