WOLLEGA UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF ELECTRICAL AND COMPUTER
ENGINEERING
DECLARATION

I am a student of Wollega university 5th year electrical and computer engineering students
in regular program who have taken my intern ship

experience in Wollega University with the host company of Damot farmer's cooperative

union agro processing industry Plc. for three months starting from 15/07/2013 to 30/10/2013
E.C.

I certify that our work is original and performed with My self with the help of gaud
line

which is given by the industry linkage office of the institute in addition to the advice
and

guidance of our advisors ……………

Approved by: -1 ___________________ _________

Signature Date

1 _____________________________ ________ _________________

2 _____________________________ ________ _________________

Academic Mentor Signature Date

AKNOWLEDGEMENT

the industry plant. I would also like to give a gratitude to all members of employers
in the

company for their contribution in knowledgeFirst of all, we would like thank to God for
his willing and giving strength to finish this
internship report. Next we would like to thank our advisor ……

and university industry linkage. Thirdly, we would like to thank Damot farmer's cooperative

union agro processing industry to give the chance to conduct in their company and also
thank

... who is a technician in the industry and gave us more knowledge about all

electrical instruments, automated control system and about electrical power installation
system in

and social life skills. Finally, we would like to thank

our university who engaged us in internship program to get practical and problem-solving
skills.

EXECUTIVE SUMMARY

This report contains the internship report that I have been performed in Damot
farmer's

cooperative union agro processing industry from march 15/2013 to may 30/2013 E.C. It

includes the background of our Internship hosting industry. The report includes our
overall

internship experience including our work tasks, benefits that we found from our
hosting

company, the challenges that we have been faced and the measures we have taken to
overcome

the challenges. The report also states the overall benefits that we earned in addition to my
works

and My recommendation for the company. On the other hand, I developed our social
and

communication skills, developed how to communicate with different class of employees how
to
communicate with an engineer, operator and technicians also developed our work with ethics
like

punctuality, working with others.

LIST OF ACRONYMS

AC……....Alternating current

CPU…… Central processing unit

DC……. Direct current

DN…… Done bit

EN ……Enable bit

IM….. Induction motor

I/O ….Input output

IR….. Infrared ray

NC ….Normally closed

NO ….Normally open

PLC…. Programmable logic controller

RLO Result of logic operation

List of figures

Figure 1. Organizational
structure ................................................................................................... 2

Figure 2. Work flows

chart .............................................................................................................. 3

Figure 3. Work flows

chart .............................................................................................................. 6

Figure 4. Pressure
fun ...................................................................................................................... 7
Figure 5. Washing
machine ............................................................................................................. 8

Figure 6. Horizontal scourer

machine ............................................................................................. 8

Figure 7. Screw
conveyer ................................................................................................................ 9

Figure 8.
Separator ........................................................................................................................ 10

Figure 9. Roller mill

machine ........................................................................................................ 11

Figure 10. PLC conceptual application

diagram ........................................................................... 25

Figure 11.
methodology ................................................................................................................. 26

Figure 12. basic part of

plc ............................................................................................................ 28

Figure 13. process of

plc ............................................................................................................... 30

Figure 14. IR
Sensor ...................................................................................................................... 32

Figure 15. DC
motor ...................................................................................................................... 33

Figure 16.
Timer ............................................................................................................................ 34

Figure 17. Flow

chart .................................................................................................................... 36

Figure 18. Functional block

diagram ............................................................................................. 37
Figure 19. Input
ladder .................................................................................................................. 37

Figure 20. Output

coil .................................................................................................................... 37

Figure 21. Simulation

diagram ...................................................................................................... 39

Figure 22. simulation result for

M1. .............................................................................................. 40

Figure 23. Simulation result for

M2 .............................................................................................. 41

Figure 24. Simulation for

M3 ........................................................................................................ 42

Table of Contents

DECLARATION ..........................................................................................................................
.... i

AKNOWLEDGEMENT ................................................................................................................
. ii

EXECUTIVE SUMMARY ............................................................................................................

iii

LIST OF
ACRONYMS .................................................................................................................. iv

CHAPTER
ONE .............................................................................................................................. 1

BACKGROUND OF THE COMPANY ......................................................................................... 1

1.1.
Introduction .......................................................................................................................... 1

1.2. Vision, Mission and Objective of the

company ................................................................... 1
1.2.1. Vision ............................................................................................................................
1

1.2.2. Mission ..........................................................................................................................

1

1.2.3. Objective of the company ..............................................................................................

1

1.3. Organizational
structure ....................................................................................................... 2

1.4. Key stake holders of the

company ........................................................................................ 2

1.5. Production process of the

company ...................................................................................... 2

CHAPTER
TWO ............................................................................................................................. 4

THE OVERALL INTERNSHIP EXPERIENCE ............................................................................ 4

2.1. Objective of the

internship ................................................................................................... 4

2.1.1. General objectives .........................................................................................................

4

2.1.2. Specific objectives .........................................................................................................

4

2.2. How we did get Gozamen Farmer's Union Company ..........................................................

5

2.3. Work
section ......................................................................................................................... 5

2.3.1. Pre-cleaning section .......................................................................................................

5

2.3.2. Cleaning section ............................................................................................................

7

2.3.3. Transferring section .....................................................................................................

11

2.3.4. Milling section .............................................................................................................

11

2.4. Overall system components and

operation ......................................................................... 12

2.4.1. Electrical circuit breaker ..............................................................................................

12

2.4.2. Contactor .....................................................................................................................

12

2.4.3. Overload relay .............................................................................................................

13

2.4.4. Motors ..........................................................................................................................

13

2.5. Major duties of the

intern ................................................................................................... 14

2.6. Challenges faced and

measures .......................................................................................... 14

CHAPTER THREE .......................................................................................................................

15

BENEFITS GAINED FROM THE INTERSHIP .......................................................................... 15

3.1. Practical
skill ...................................................................................................................... 15

3.2. Theoretical
knowledge ....................................................................................................... 15

3.3. Team playing skill ..............................................................................................................

15
3.4. Inter personal
skill .............................................................................................................. 15

3.5. Leader ship skill .................................................................................................................

16

3.6. Based on work

ethics .......................................................................................................... 16

3.7. Based on interpersonal

communication .............................................................................. 16

Conclusion ...............................................................................................................................
.. 18

Abstract ...................................................................................................................................
... 20

CHAPTER
ONE ............................................................................................................................ 21

INTRODUCTION AND BACKGROUND .................................................................................. 21

1.1. Statement of
problem ......................................................................................................... 22

1.2.
Objective .............................................................................................................................
22

1.2.1. General objective .........................................................................................................

22

1.2.2. Specific objectives .......................................................................................................

22

1.3. Significance of the

study .................................................................................................... 23

1.4. Scope of the

project ............................................................................................................ 23
1.5. Limitation of the
project ..................................................................................................... 23

CHAPTER
TWO ........................................................................................................................... 24

Literature
Review .......................................................................................................................... 24

2.1. Basic parts of

plc ................................................................................................................ 25

CHAPTER THREE .......................................................................................................................

26

Methodology ...........................................................................................................................
....... 26

3.1.
Introduction ........................................................................................................................ 26

3.2. Project over

view ................................................................................................................ 27

3.3. Introduction to several basic Electrical Components .........................................................

27

3.3.1. Programmable logic controller (PLC) ......................................................................... 27

3.3.2. Ladder logic diagram ...................................................................................................

28

3.3.3. Elements of ladder diagram .........................................................................................

29

3.3.4. Operation of PLC ........................................................................................................ 30

3.4. Input
module ....................................................................................................................... 31

3.5. Signal
conditioning ............................................................................................................. 32
3.6. Output
module .................................................................................................................... 33

3.7. Flow
chart ........................................................................................................................... 35

3.8. Functional block

diagram ................................................................................................... 36

3.9. Input and Output

assignment .............................................................................................. 38

3.10. Simulation diagram ..........................................................................................................

39

CHAPTER
FOUR ......................................................................................................................... 40

Result and
Discussion .................................................................................................................... 40

CHAPTER
FIVE ........................................................................................................................... 43

Conclusion and
Recommendation ................................................................................................. 43

5.1.
Conclusion .......................................................................................................................... 43

5.2.
Recommendation ................................................................................................................ 43

Reference ................................................................................................................................
....... 44

CHAPTER ONE

BACKGROUND OF THE COMPANY

1.1. Introduction
Damot farmer's cooperative union agro processing industry is founded in 2005 E.C. in

Burie The Company is found at the industry zone, Keble 05, about 3km south west from

Burie town Central……………………………………………………..

. The company is owned by unity of farmers.

The companies cost a total capital of 17,800,000 birr to buy and install the machine.
The

company is landed on 30,000 square meter area. Damot farmer's agro processing meal flour

industry has a Crushing capacity of 840 quintals per day. It has a total of 52 workers.

1.2. Vision, Mission and Objective of the company

1.2.1. Vision

To become leading industry which produces a quality wheat flours for bread, spaghetti, biscuit

and macaroni to be an input for the future planed food complex industries expanded
of the

industry.

1.2.2. Mission

✓ To supply wheat flour that is leaders in quality, cost and customer satisfaction.

✓ To provide market connection with regional farmers.

✓ To be an input for the future planed food complex industries expanded of the industry.

1.2.3. Objective of the company

The company has the following objectives:

-✓ Agricultural input and output marketing

✓ Consumer goods marketing

✓ Training service

✓ Transportation service
✓ Marketing information service and

✓ Community concern service for farm

1.3. Organizational structure

Figure 1. Organizational structure

1.4. Key stake holders of the company

Damot farmer's cooperative union agro processing industry is owned by the association
of

peoples that lives in west gojjam zone.

1.5. Production process of the company

Generally, the production process may be classified into three basic groups. These are: -

✓ purchasing raw material,

✓ producing the product and

✓ Sales the product.

But there are a number of process and operations especially under processing and producing

the product group. This group may also subdivide in to pre-cleaning, cleaning, milling,

purifying and packing operation process.

Figure 2. Work flows chart

CHAPTER TWO

THE OVERALL INTERNSHIP EXPERIENCE

The industry consists a full of huge machines for producing its product and we had not expect
the

industry to have such type of machines. Because we have known different milling houses in
our

village and all of them are working in simple and easy way that is simply milling operation
only.

2.1. Objective of the internship

2.1.1. General objectives

The main objective of the internship was to gain an experienced practical knowledge in
different

electrical equipment’s and control automation systems by inter-relating with the

theoretical

knowledge and to upgrade our technology. Internships will provide us the opportunity to test
their

interest in a particular career before permanent commitments are made. Apart from this it
has the

following advantages:

✓ I will develop skills and techniques directly applicable to the careers we hold.

✓ Internships will provide us the opportunity to develop attitudes conducive to effective

✓ Inter personal relationships.

✓ Internships will provide us to have depth knowledge of the formal functional activities of
the
participating organization.

✓ Internship programs will help to develop problem solving skill.

✓ The internship is to enable students relate their theoretical knowledge to the actual
practice

in the real world of work place.

2.1.2. Specific objectives

✓ To provide intensive field experience allowing for hands-on computer work

✓ To receive an introduction to an organization within the Information Systems industry and

to

gain a better understanding of its design and structure.

✓ To develop an understanding of an organization's various management and technical skills,

the communications techniques and the decision-making processes.

2.2. How we did get Damot Farmer's Union Company

We ask the company manager of Damot Farmers’ cooperative union to accept the internship

paper and he accepted our request openly in order to take the internship experience in
Damot

frer’s cooperative union.

2.3. Work section

I am working in all section of the ago processing industry from pre-cleaning to the grinding

process. pahen I stay in the industry, I have been working in pre-cleaning, cleaning,
and

transfer and milling process so I start our work from pre-cleaning of the wheat. There are
four

main sections I have been working. These are:

1. Pre-cleaning

2. Cleaning

3. Transfer section

4. Milling

2.3.1. Pre-cleaning section

In this section I saw a lot of technique how to produce clean wheat. Put through
special

cleaning machines and magnets to remove foreign objects such as dirt, straw, stones and
metals.

First the wheat flow from the store to the elevator and pushes the wheat to the cleaning
section

before coming to the cleaning there is steel and wheat separator that separate
magnetic

component from the wheat and other non-metal components are transfer to the
separator it

separates the wheat from non-wheat shaped component like stone, soil etc.

A. Air lock

As the name indicates it used to separate air from the product, which is discharged
from a

cyclone separator into pneumatic systems. It receives dust and dust like components and
then it

transfers the dust to the upper atmosphere and large weight from the dust to the bottom
garbage.

This air lock receives the air from the low-pressure pump motor and it rotate the
turbine to

produce air and then the wheat shaped components and the wheat transfer to the next
elevator.
B. Storage

It is the storage of wheat which is ready for processed in rectangular hollow section which has
a

slanting /inclined bottom/floor that enables to slide the wheat through the exit gate.

It can hold around ten tons of wheat. The exit gate is mounted at the bottom
boundary of

separation wall of the storage and pre-cleaning and the exit gate is a mechanical device which

used for opening and closing the wheat storage as shown the figure When the wheat quality
is

certified by the chemist laboratory technician, it discharges at the top of the storage hole until
it

become full.

The technician reports the characteristics of the wheat for the operators in order to maintain
the

machine based on these characteristics.

Figure 3. Work flows chart

C. Bucket Elevator

Bucket elevators transports wheat and the wheat flour vertically by means of a seriously
arranged

Spade which is mounted on the rotated belt. The working principle is based on gravity
and

centrifugal force, the wheat is received from the bottom due to gravity and fills the rotated
spade

which reaches to the bottom and elevated at an available position and discharges to
the next

process due to the combination of continuous gravity and centrifugal forces.

D. High- and Low-Pressure Fan

The high-pressure fan used to generate high pressurized air in order to transport or convey
the

wheat flour after milling operation to different sieving and purification system of
different

machines up to the final output. And low-pressure fan is functional for separating
unnecessary

light materials in each cleaning operations on the machine

Figure 4. Pressure fun

2.3.2. Cleaning section

For the next cleaning section, the wheat transfer by the elevator and it transfer to the
separator.

The storage that holds the wheat has dispensers which may mix various batches of different
types

of wheat to produce the final flour product. During this process the wheat is cleaned once
again

to remove any remaining small impurities like seeds and broken wheat. It is then brushed
again to

remove the outer layer and then put through the de-stoner to remove any remaining stones.
It is

then disposed into a hydrating machine where water is added to bring the wheat to the
humidity

levels required for processing. The wheat is then stored in the tempering storage for a specific

amount of time.

1. Wheat Washing Machine

Wheat washing machine adopts wet method to clean wheat. It is applicable in flour
milling

machine to remove stones and sands in the wheat cleaning process. In the process, the
wheat

washing machine can remove the dust on the surface and in the ventral groove of the wheat,
as

well as pesticide, microbes and pollutes. In the meanwhile, the wheat washing machine can
increase the moisture of the wheat and change

the physical property and grinding procedure in conjunction with wheat tempering
Figure 5. Washing machine

2 Horizontal Scourer machine

The horizontal scourer machine is normally equipped with as aspiration channel or a

recycling

aspiration channel at its outlet. It can efficiently remove detached hull particles or
surface

contaminations from the wheat. It also used for scouring of wheat by which it
removes outer

layer of the wheat and also soft mud stones which comes along with wheat and to
remove light impurities by air aspiration.
Figure 6. Horizontal scourer machine

3. Screw conveyers

Screw conveyor, also known as auger conveyer, is a type of continuous conveyer

equipment

without flexible medium.

Instead it transfers stock along trough with the aid of the thrust force produced by rotating
screw

blades. In this industry screw conveyors are used to move the wheat horizontally from
one

process to the other.

Figure 7. Screw conveyer

4 Separator

It used to separate coarse and fine harmful particles from the wheat by using two vibes motor

arranged at two different sides that enables to vibrate the sieves deck.

Working principles:-
✓ The sieve box set up, which is installed or rubber springs based on the device frame, moves

backwards and forwards by the two vibes arranged at each side from the machine.

✓ The separator separates the wheat from coarse and fine harmful particles by browsing.
Low-density (light) contaminates with the wheat may also be dependently by furthermore
using

an air- recycling aspiration.

Figure 8. Separator

5 Dry Stoner Machine

It could remove light stones whose sizes are similar to grain size. It is employed for the

continuous stone removing process, and it also fits for the classification of heavy and light
grains.

Its shape looks like separator machines.

Working Principle: -

There is a big difference in the suspending speed between grain and high-density materials
such

as stones, metals and glasses, while the suspending speed for heavy and light grains also
varies.
Based on these, the mixed heavy impurities will be separated from the grains, and
effective

gradation between heavy and light grains is achieved.

6 Trier Machine

Trier is used for selecting the round and long shaped substances from the pure wheat like
barley,

rye, broken wheat, crown vetch, black, grass, and embryos inside of the wheat. The
rollers

pressed on the sheet, with different diameters and the depth of which are standard
according to

the quality and the kinds of wheat to be cleaned are driven by a motor redactor. The stage
wheat

is collected with the help of spectral collectors retaken at the exit of the machine by the
screw,

which is at the center of the rollers.

The separated wheat is sorted through the control Trier in order to re-select the wheat mixed
in

the unwanted substances.

2.3.3. Transferring section

After washing the wheat, it transfers to the third section that is transferring section
store and

conveyer for this section the wheat needs eight hours for during. After eight hours the
conveyer

rotates and push the wheat to the elevator and the elevator transfer the wheat to the next
section

that is grinding section.

2.3.4. Milling section

The roller mill is one of the key equipment in wheat flour processing plants, and it is used to

grind the wheat in order to obtain flour and semolina. The roll pack design found in many
newer

roll stands allows for more stable grinding and improved precision of granulation.
Within the

input pip there is a capacitive sensor that senses the amount of wheat in the pipe. When the
sensor

reading is 20-80 the grinding motor start run. but below 20 there is low input then the
grinding

motor can stop working. Four different milling methods were used with the goal of obtaining
a

coarse, medium, fine, and extra-fine granulation out of each wheat sample.

Figure 9. Roller mill machine

Working Principle

The parallel working rolls are automatically opened and closed by pneumatic system, which is

actuated by an electric control unit.

The clean wheat enters the roller mill through a glass spout and the grinding process
starts.

Capacitive level indicators adjust the amount of wheat, which enters the rolls mill from its
inlet,

which flows regularly through the rolls, undergoes processing.

The adjusting system, which provides a very precise approach of the rolls to each other, can
be

easily integrated to the automation system. The air, which is sucked by means of a
pneumatic

system via specially created air channels, provides regular flow of grain between the rolls. The

efficiency of the roller mill is increased due to such feature. The grinded product is discharged

into a hopper, which is placed underneath the roller mill and then conveyed by means
of

pneumatic system.

2.4. Overall system components and operation

2.4.1. Electrical circuit breaker

✓ Is a device designed to open and close a circuit by non- automatic means and to
open the

circuit automatically on a predetermined over-current without injury to itself when properly

applied within its rating. So, a circuit breaker is a combination device composed of a
manual

switch and an over current device.

Operation of circuit breaker

In order to allow power to pass through the breaker, the operating lever is placed in
the on

position. This mechanically closes the contact in the breaker. When current pass
through the

device a magnetic field is developed in the bar. The intensity of this fields focuses through a
large

piece of metal at the end of movable arm-. When the current existed as predetermined
amount,
the magnetic field will pull to the right, releasing the lever and the trip mechanism, allowing
the

spring to pull contact open.

Function of Circuit breaker

✓ Circuit breakers as switch - A circuit breaker can control and protect an electrical circuit.

✓ As over current protection - open the circuit automatically on a predetermined over

current

without injury to itself.

2.4.2. Contactor

Contactor is having only one position of rest, operated electromechanically and capable
of

making, carrying and breaking currents under normal circuit conditions, including
overload

operations. A contactor does not provide overload protection. Contactors are used to
electrically

turn on or off electrical circuit when current pass

Operating principle of Contactor

When current passes through the electromagnet, a magnetic field is produced; this
attracts the

moving core of the contactor. The electromagnet coil draws more current initially, until
its

inductance increases when the metal core enters the coil. The moving contact is propelled by
the

moving core; the force developed by the electromagnet holds the moving and fixed
contacts

together. When the contactor coil is de- energized, a spring returns the electromagnet core to
its
initial position and opens the contacts.

2.4.3. Overload relay

Relays control current flow in a circuit based on signals obtained from an information source.
A

relay is a simple electromechanical switch made up of an electromagnetic coil and a

set of

contacts. An electric signal (Voltage) gets sent to the coil creating a magnetic field, closing the

armature, which closes Normally Open (N.O.) and opens Normally Closed (N.C.) Contacts.

Operation principle of overload relay

A relay is an electro-magnetically operated switch. It consists of an operating coil wound

around

an electromagnet pole piece, a moving armature and one or more sets of contacts. When a
voltage

of the correct value is applied across the coil terminals, the resulting current flow through the
coil

produces a magnetic field similar to a bar magnet.

2.4.4. Motors

Induction motor (IM) is mostly used in Damot farmers union.

Induction motor (IM)

It is AC motor that converts electrical energy in to mechanical energy when the 3-phase
stator

winding are fed by a 3-phase supply then a magnetic flux of constant magnitude but rotating
at

synchronous speed is setup the flux pass through the air gap sweeps past the rotor surface
and so

cuts the rotor conductors which as yet stationery.

According to electro-magnetic induction when a current carrying conductor is placed in
a

magnetic field the conductor experiences a mechanical force. In Damot farmer's cooperative

union, there are many induction motors which are used to move from one process to the
other

process. With respect to size and power rating, there are two types of induction motors;

✓ Small sized IM-have power rating less than or equal to 3kW and connected directly to three

phase voltage. Conveyor drives, elevators, low pressure fan and most others found in

Damot farmer's cooperative union are small sized induction motors and use power up to 3

KW.

✓ Bigger sized IM- have power rating of greater than 3KW, and operate with line voltage of

400V which are started in star-delta. High pressure fan, horizontal scorer and some
other

machines use bigger sized induction motor.

2.5. Major duties of the intern

✓ Punctuality

✓ Loyalty

✓ Open minded

2.6. Challenges faced and measures

Challenges we faced

In our working place we faced some Challenges. These are: -

✓ my internship company is not voluntary to give us the machine working manual.

✓ Not voluntary to show the internal parts of the machine.

✓ They don’t give real information for some machines especially on sensors, how they work.
✓ The absence of workshop to perform a proper job.

✓ No proper tools for maintenance work.

Measures we have taken in order to overcome challenges

✓ We solve this problem by:

-✓ searching the manual from the internet to read and understand the working principles

✓ By watching related video.

✓ And also take oral presentation from the operators.

CHAPTER THREE

BENEFITS GAINED FROM THE INTERSHIP

3.1. Practical skill

✓ I have developed our self-confidence in operating of the machine as well as maintenance

works.

✓ I can know different rules for easy detecting of failed parts by inspection

✓ I know different procedures of maintenance starting from cleaning up to proper

disassemble and assembly procedures.

3.2. Theoretical knowledge

I have developed a great image on theoretical knowledge what we have taken in university by

relating different operating systems, power transmitting system and their working principle.
Even

I have known benefits of supportive courses and its theoretical knowledge application in the

industry Like reasoning skill.

3.3. Team playing skill

The first step to start our internship were adapting the behavior of the workers and
supervisors,
these were benefited to improve our interpersonal skills. when I work with a team, I got the

following interpersonal skills to be efficient in team work.

✓ Be conducive to team building

✓ Raise the workers “morale‟

✓ Acquire the polite (well manner) habit

✓ Improved work efficiency

✓ Acquire the habit of obeying rules

3.4. Inter personal skill

These principles of personal skills are values that are expected to be possessed by all
individuals

in their life and contribute a lot for smooth interactions among individuals and peaceful

co existence of society. What I gained in the company principles of personal ethics include;

✓ Concern for the wellbeing of others

✓ Honesty

✓ Fairness

✓ Compliant to the law

3.5. Leader ship skill

In working places we will meet different people and different problems we must take
measures to

these problems. When someone gets in leadership position he has a responsibility to

customers,

to the staff, to shareholders and to the society.

❖ To customers:

✓ High quality
✓ Reasonable prices

❖ To the Staff :

✓ Compensation

✓ Welfare

✓ Promotion

❖ To the Shareholders:

✓ Profit

✓ Investment return

❖ To the Society:

✓ Good production

✓ Legal taxation

3.6. Based on work ethics

In the industry all workers and leaders are ethical this is due to the development of
love and

honesty among them that is built by the leaders. So I have known everything become
fine with

love and honesty.

3.7. Based on interpersonal communication

I have developed our interpersonal communication in the industry since each activates
are

performed in Individual due to the nature of the machines property and assembling
procedures.

Not only this but also every activity and problems are reported and documented in every time
for

the feedback for the future operation, adjustment and maintenance. So without
communication

there is no existence in the industry

Conclusion

In these three months of our internship we saw and learn a lot of things about wheat
flour

production industry. How to produce wheat flour is along and interesting work, I learned
about.

How quality means and in what procedures and methods can I keep the quality. I
learned

wheat flour production process from pre-cleaning to grind the wheat. When I stay in
the

industry I got a lot of skills so if I got a chance I can do the whole workers of wheat
flour

production.

PART TWO

PROJECT ON

Plc Based Automatic Sack Filling and

Sewing System

Abstract

The project deals with the automatic sack filling and sewing system in wheat flour industry

using PLC. This system gives a fast and efficient operation of task reducing manual control.

The controller for this system is supplied by a single-phase DC power supply. The program
defines the kind of task to be performed on the system corresponding to the inputs. This

control program is fed to the controller using a programming logic control device (PLC).

The system sequence of operation is designed by ladder diagram and the programming of

this project by using LOGO-programmer software.

CHAPTER ONE

INTRODUCTION AND BACKGROUND

Programmable Logic Controller (PLC) is a digital computer for automation of process such

as control of instruments in industries. It uses a programmable memory to store instructions

and specific functions that include ON/OFF control, timing, counting, sequencing,

arithmetic, and data handling. The basic parts include processor, input/output devices,

memory unit, programming panel and power supply. Static Application Panels (SAP) is

designed to produce input and output from the PLC. Early electrical control systems were

composed of mainly relays and switches. A relay, or contactor, is an electromagnetic device

composed of a frame (core) with an electromagnet coil and contacts with some movable and

some fixed parts. Due to its disadvantages like chattering, complicated wiring and less

flexibility relays are replaced by PLC. The SAP panels and ladder programmers were

developed for automatic bottle filling machine, water level controller, logic gates, counter

and comparator. Ladder programmer is downloaded into PLC and verified with SAP model.

According to the condition and comments provided in the ladder program the SAP model

works, if any deviation in the comments provided and this can be modified in the ladder

diagram. This paper explains about the PLC and ladder diagram designed for automatic

sack filling and sewing system. In the past, humans were the main method for controlling a

system. More recently, electricity has been used for control and early electrical control was
based on relays. These relays allow power to be switched on and off without a mechanical

switch. It is common to use relay to make simple logical control decisions. The

development of low cost computer has brought the most recent revolution, the

Programmable Logic Controller (PLC). The advent of the PLC began in the 1970s, and has

become the most common choice for manufacturing controls. It is a system which consist

many processes together and these are:

✓ Plc

✓ Automation

✓ Sack filling and

✓ Sewing The static application panels (SAP) are simulation modules of various
applications that

usually come across in industrial environment such as motor control, level controlling, and

process controlling, industrial automation. For each SAP model, panels are designed

accordingly. Terminals to connect input and output are brought outside the panels. SAP

modules are just input and output devices to PLC. The Input is given from a push button or

Toggle switch representing a sensor or a switch. The output is connected to a LED

indicating a motor or a relay or a bulb status whether ON/OFF. All the panels have different

problem statement to be solved. These SAPs are just simulation modules and not exact

working modules. But they use all the parameters required in the exact applications. Instead

of motor LED is switching on or toggle switch is used for sensing the object or starting the

process cycle. Where in the real application motors, proximity sensors and limit switches

are used for control application. SAP models are designed with care so that the connections

can be made very easily and self-explanatory. The system works on 230V 50Hz AC Mains.
Each SAP module requires digital input and digital output. In the main panel of PLC the

digital I/O‘s are brought out to the panels and clearly designated.

1.1. Statement of problem

The Damot Farmers’ cooperative union agro processing industry has many problems. I

focused on the sack filling and sewing system only which include some its own specific

problems which are sack filling and sewing systems are manually as they need more human

power.in the company after the mailing for filling human power is mandatory there is no

automatic filling machine and sewing machine.to solve this problem. I have done

automatic sack filling and sewing system by using plc software.

1.2. Objective

1.2.1. General objective

The general objective of the study is to design automatic sack filling and sewing

system through programmable logic controller (PLC).

1.2.2. Specific objectives

The specific objectives are:

✓ To develop the ladder program for automatic sack filling and sewing system.

✓ To simulate automatic sack filling and sewing system using LOGO Software. 1.3.
Significance of the study

The design and simulation of the automatic sack filling and sewing system will offer a good

sack filling and sewing system to the workers (owners) who have get their wanted products

using Programmable logic controller-based technology. The application of programmable

logic controller (PLC) technology to sack filling and sewing for an efficient and more

convenient for all industries thereby providing significant economic impact.

1.4. Scope of the project

In this project it is trying to simulate the model by using PLC The scope of this
project is to

develop soft ware.in this software development there are two main sections and that sections
are:

✓ To select and develop soft ware

✓ To simulate the control system

1.5. Limitation of the project

✓ In our project we have use infrared sensor. But we have not got the sensor in the
plc

directly we use switches as a sensor.

✓ The plc uses DC power only

CHAPTER TWO

Literature Review

Long time ago people were using traditional method of filling flour in to their containers or
sack

and sewing them traditionally. This was very time-consuming work and consume energy to
do

the work hardly.

PLC was first introduced in 1960‟s as a substitute for hardwired relay panels. The primary
reason

for such a device was eliminating the large cost involved in replacing the complicated
relationbased machine control system. [2].

PLC (Programmable Logic Controller): A Solid-state control system that has a user

programmable memory for storing instructions for the purpose of implementing specific

functions such as I/O control, logic, timing, counting, communication, arithmetic and data
and

file Processing. [2].

PLC is a digital computer used for automation of industrial processes, such as control
of

machinery on factory assembly lines. It is designed for multiple inputs and output
arrangements.

A PLC is an example of a real time system since output results must be produced in response
to

input conditions within a bounded time, otherwise unintended operation will result.

PLC is a device that was invented to replace the necessary sequential relay circuits for
machine

control. It works by looking at its inputs and depending upon their state, turning
on/off its

outputs. The user enters a program, usually through software, that gives the desired results.
PLC

is used in many “real world” applications. [5].

A programmable logic controller, commonly known as PLC, is a solid state, digital, industrial

Computer using integrated circuits instead of electromechanical devices to implement

control

Functions
. Figure 10. PLC conceptual application diagram

2.1. Basic parts of plc

All programmable controllers contain a CPU, memory, power supply, I/O modules, and

programmable devices. Basic parts of the PLC are as follows: -✓ Programming device

✓ Memory

✓ Input/output devices

✓ Central processing unit (CPU)

✓ Power supply

Programming device- Is used to enter or change the user program into the memory and
monitor

the program execution.

Memory– stores programs and data that the CPU needs to perform various operations.

Input output device - Moves data between the computer and its external environment

Central processing unit- Controls the operation of the PLC and performs its data
processing

functions; often simply referred to as processor.

Power supply- provides voltage levels required for internal operation. Its responsibility is not

only to provide internal DC voltages to the system components (i.e., processor,

memory, and

input/output interface modules), but also to monitor and regulate the supplied voltages and
warn

the CPU if something is wrong. The power supply, then has the function of supplying
wellregulated power and protection for other system component. (typically ±5 v dc or±12 v
dc)
CHAPTER THREE

Methodology

3.1. Introduction

This chapter will mainly discuss about the methodology of the project and also the
aspect or

factors that must be taken into consideration during the development process. All this
factors

were very important to make sure the project will achieve its objective. The method
we have

followed in our work is as follow

Figure 11. methodology

3.2. Project over view

In this section, we will discuss an over view of automatically filling sack and sewing
system

using plc. The introduction to system task will also briefly explain.

3.3. Introduction to several basic Electrical Components

There are many electronic components that can be used during the development of

automatic sack filling and sewing system are familiar with and some are rarely used. All

components play its important role and interrelated between each other in completing the
circuit design.

3.3.1. Programmable logic controller (PLC)

A programmable logic controller (PLC) is a special form of microprocessor. Based on

control system that uses a programmable memory to store instruction (Boolean logic,

sequencing, timing, counting arithmetic, relay, function block, and special instruction) and

to implement functions in order to control machines process and designed to be operated by

technicians or engineers with perhaps a limited knowledge of computer and computing

language.

They are not designed so that only computer programs can setup or change the program.

Thus the designer of the PLC have per-programmed it so that the control program can be

entered using a simple, rather intuitive form of language. The term logic is used because

programming is primary concerned with implementing logic and switching operations.

Input device such as sensors, switches, etc. and output device such as motors, valves, etc.

are connected to the PLC. Then operator enters a sequence of instruction, i.e. a program,

into the memory of the PLC. The Controller monitors the input and output according to this

program and carries out the control rules for which it has been programmed. A

Programmable Logic Controller (PLC) is a digital computer used for automation of

industrial processes, such as control of machinery on factory assembly lines. Unlike

general-purpose computers, the PLC is designed for multiple inputs and outputs

arrangements, extended temperature ranges, immunity to electrical noise, and resistance to

vibration and impact. Programs to control machine operation are typically stored in
batterybacked or non-volatile memory. [7]

A PLC is an example of a real time system since output results must be produced in
response to input conditions within a bounded time, otherwise unintended operation
will

result.

Figure 12. basic part of plc

A Programmable Logic Controller (PLC) is a device that was invented to replace the

necessary sequential relay circuits for machine control. The PLC works by looking at its

inputs and depending upon their state, turning on/off its outputs. The user enters a program,

usually via software, that gives the desired results. PLC is used in many ―real world‖

applications. If there is industry present, chances are good that there is a PLC present.

Almost any application that needs some type of electrical control has a need for a PLC.

3.3.2. Ladder logic diagram

Ladder logic diagram is the main programming method used for PLC. The use of ladder

programming involves writing a program in a manner to drawing a switching circuit. The

ladder

diagram consists of two vertical lines representing the power rails, and circuits are connected
as

horizontal lines. Ladder logic instructions work with two digits, 1 and 0. These two digits form

the base of a number system called the binary system. The two digits 1 and 0 are called
binary

digits or bits. In the world of contacts and coils, a 1 indicates activated or energized, and a
0

indicates not activated or not energized.

The bit logic instructions interpret signal states of 1 and 0 and combine them
according to

Boolean logic. These combinations produce a result of 1 or 0 that is called the “result of logic

operation” (RLO).

3.3.3. Elements of ladder diagram

Ladder logic inputs: PLC inputs are easily represented in ladder logic. In our project we use

two logic inputs.

These are:

----| |--- Normally Open Contact

---| / |--- Normally Closed Contact

A) ---| |--- Normally open contact

Symbol

<Address>

--| |---Description

---| |--- (Normally Open Contact) is closed when the bit value stored at the specified
<address>is

equal to "1".When the contact is closed, ladder rail power flows across the contact and the
result

of logic operation (RLO) = "1".Otherwise, if the signal state at the specified <address>is "0",
the

contact is open. When the contact is open, power does not flow across the contact and the
result

of logic operation (RLO) = "0".

B) ---| / |--- Normally closed contact

Symbol
<Address>

---| / |---Description

---| / |--- (Normally Closed Contact) is closed when the bit value stored at the
specified

<address>is equal to "0". When the contact is closed, ladder rail power flows across the
contact

and the result of logic operation (RLO) = "1". Otherwise, if the signal state at the
specified

<address>is "1", the contact is opened. When the contact is opened, powe r does not flow
across

the contact and the result of logic operation (RLO) = "0".

---| / |--- (Normally Closed Contact) is closed when the bit value stored at the
specified

<address>is equal to "0". When the contact is closed, ladder rail power flows across the
contact

and the result of logic operation (RLO) = "1". Otherwise, if the signal state at the
specified

<address>is "1", the contact is opened. When the contact is opened, powe r does not flow
across

the contact and the result of logic operation (RLO) = "0".

Ladder logic outputs

Symbol

<Address>

---( )

Description

( ) (Output Coil) works like a coil in a relay logic diagram. If there is power flow to
the coil

(RLO = 1), the bit at location <address>is set to "1". If there is no power flow to the coil (RLO =

0), the bit at location <address>is set to "0". An output coil can only be placed at the right end
of

a ladder rung.

3.3.4. Operation of PLC

A PLC works by continually scanning a program. We can think of this scan cycle as

consisting of 3 important steps. There are typically more than 3 but we can focus on the

important parts and not worry about the others. Typically, the others are checking the

system and updating the current internal counter and timer values. [5]

Figure 13. process of plc

Step 1- Check Input Status: First the PLC takes a look at each input to determine if it is on

or off. In other words, is the sensor connected to the first input on? How about the second

input? How about the third... It records this data into its memory to be used during the next

step.

Step 2- Execute Program: Next the PLC executes your program one instruction at a time.

Maybe your program said that if the first input was on then it should turn on the first output.

Since it already knows which inputs are on/off from the previous step it will be able
to
decide whether the first output should be turned on based on the state of the first input. It

will store the execution results for use later during the next step.

Step 3- Update Output Status: Finally the PLC updates the status of the outputs. It updates

the outputs based on which inputs were 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 was on and your program said to turn on the
first

output when this condition is true. After the third step the PLC goes back to step one and

repeats the steps continuously. One scan time is defined as the time it takes to execute the 3

steps listed above.

3.4. Input module

Input Module in other word are Sensors. Such a sensor includes:

✓ The present and Absence of the sack, this will be IR.

✓ A sensor that detect whether the sack is full or not, this can be Weight Sensor.

✓ Limit switch sensor to detect the arrival of an object to a certain position.

The following are the input modules (Sensors)

✓ Infrared Sensor

✓ Weight Sensor

✓ Limit switch

Infrared ray sensor (IR)

This sensor provides the system with ability to detect the presence of object position. The
theory

is the IR emitter emits infrared light. If an object presence the signal will be reflected back to
the
receiver. Then the IR detector implemented will detect the reflected light. Then the

correspondence signal sends to the PLC for being analyze. Based on the measurement
of the

intensity of the reflected light from the target area such a sack, it has a light source se nding
light

to the moving target and a light sensor receiving the light.

The output signal from the sensor decreases exponentially with the increase of the distance
to the

measured object. Infrared light-emitting diodes (LED's) and photosensitive diodes are used in
this

transducer.

Figure 14. IR Sensor

Limit switch

A limit switch is an electromechanical device that consists of an actuator mechanically linked

to a

set of contacts, when an object comes into contact with actuator the device operates the
contacts
to make or break an electrical connection. Limit switch are used in a Varity of applications
and

environments because of their ruggedness, ease of installation, and reliability of operation.

They

can determine the presence or absence, passing, position, and end of travel of an object .in
this

project we use it to detect the arrival of the sack to the desired position to do the processes
such

as sewing. The limit switches are mounted at the edge of the conveyor before sewing
machine.

3.5. Signal conditioning

Variable conversion: this is to convert signal from one form to another. Which includes:-✓
Rectification

✓ Inversion

✓ Analog to digital conversion or inverse

Variable manipulation: the level of output from the previous stage may not drive the next
stage,

thus signals should be manipulated. This includes: -✓ Amplification

✓ Filtration

✓ Modulation or demodulation

3.6. Output module

The various output devices used in the sacking process are gear motors, pumps, actuators.
The

gear motor is used to run the conveyor in forward direction. Actuators are used for sewing the

sacks and to open or close the flour filling valve. The actuator applies a force on the sack
which
in turn sewing the sack tightly. These are the various output devices u sed in the sewing
process.

The output modules are:-✓ DC motor

✓ Conveyer belt

✓ Timer

✓ Gate valve

D C Motor: -is a small electronic device that can move if the power supply is connected. It
main

function is to make the Conveyer belt moves perfectly.

Figure 15. DC motor

Conveyer belt: -are used to carry the sack to the track to be filled. It will be made of
PVC

(polyvinyl Chloride) to allow for the sack to slip. Also, this will enable us to use a DC motor
with

relatively small output power and low speed.

Timer:-are used to activate or deactivate a device after expired intervals .timers has an

accumulator resistor to store the elapsed time and a register to store the preset value. The
length

of the time delay is determined by specifying a preset value.

The Enable bit EN is set to 1 when there is a logic path to the time. the done bit DN indicates
the

status of the timer and set to 1 when the accumulated value equals the preset value.
Figure 16. Timer

There are three types of timers. These are: -On-delay timer: when the inputs is on it waits y
second to turn on the output.

Off-delay timer: when the inputs is off it waits x second to turn off the output.

Retentive timer: is a timer which retains the accumulated value in case of power loss, change
of

processor mode or rung state going.

N.B In our project we use retentive type of timer

Gate valve

Gate valve is an instrument that can be opened and closed to allow or prevent flow of
materials.

In our project we use mechanical valve which is driven by pressure force to open and
close

conveyor as well as gate source.

Filling process

IR Sensor (Photo Sensor) or infrared ray sensor is used at the start of the system to detect
whether

the sack are ready to the filling system or not.

At this point when IR (Photo sensor) detects the position of the sack Motor-1 will be ON and
the
filling process takes place. The flour will continue to flow until the desired weight is obtained.

When the desired weight has been filled into the sack the balance or (weight sensor) alerts
the

system that the desired amount of flour has been reached. Consequently, the PLC sends a
stop

signal to motor-2 to close the valve, thus stopping the flow of flour to the sack. After this is
done,

the filling valve becomes closed and conveyer belts or (motor-3) start moving towards sewing

machine.

3.7. Flow chart

Flow chart is ideal for a process that has sequential process steps. The step will be executed in
a

simple order that may change as a result of some simple decisions.

A flow chart shown in

fig 17. for a control system of automatic sack filling and sewing.

Figure 17. Flow chart

3.8. Functional block diagram

It is used for plc program described in terms of graphical blocks. It is described as

being a

graphical language for depicting signal and data flows via blocks, these being reusable
software

elements. A FBD is a program instruction unit which, executed yield one or more output
values.

Thus, a block is represented in the manner shown in Figure with the function name written in
the

box.

Figure 18. Functional block diagram

Basic functional ladder logic diagram symbols

PLC functional ladder diagram logic consists of a commonly used set of symbols that
represent

instructions. Understanding these basic symbols is essential to understanding PLC operation.

For

our project, to simulate it we use the function ladder diagram (FLD) language. The component

and description of thus are:-Input ladder: represent the input terminals of LOGO.

Figure 19. Input ladder

Timer: the ladder shows three types of timer contacts.

Output coil: Output coil represent the output terminals of LOGO.

Figure 20. Output coil

3.10. Simulation diagram

Figure 21. Simulation diagram

CHAPTER FOUR

Result and Discussion

Figure 22. simulation result for M1.

When the sack come by the conveyer the IR sensor send signal to plc, then the controller
turns on

the motor M1.Q1 indicate the conveyer is active to carry the sack. If the incoming
sack is

finished IR sensor become off (cannot sense) as result motor off (M1).
Figure 23. Simulation result for M2

When the sack is filled, the IR send signal to the plc. Then the controller turns on the motor
(M2).

Q2 indicated the filler machine is active. If the sack is filled IR sensor becomes off (cannot
sense)

as a result motor (M2) off.

CHAPTER FIVE

Conclusion and Recommendation

5.1. Conclusion

In our project we have done the plc-based sack filling and sewing system. this project is
normally

very important for the company owners because it reduce human power in the company.at
the

present time sack filling and sewing is manually. At least three or four persons are
mandatory.so

in order to solve this problem we have to developed the above system by using plc
LOGO

software. After this time only one person is enough necessary for controlling purpose. Then
we

can conclude that this project can reduce human power in the company by 75% of the
previous

human power.
5.2. Recommendation

Actually, a lot of weakness from the project can be taken as future works because the
improved

system will be better in performance. The performance of Automatic sack filling and
sewing

System can be increased based on the following recommendations which are:

✓ The proposed system now uses only one sensor that is IR sensors to detect position of

flour inside the sack

✓ Now we designed with software, for the future we want to design by using hardware.

Reference

[1] Bateson, N.R. ‘‘Introduction to Control System Technology’’, Sixth Edition, United State of

America: Prentice Hall.1999.

[2] Colin D. Simpson, ‘‘Programmable Logic Controllers Regents Prentice Hall’’

[3] Lug, J. Y. S., Walker, M. W., and Paul, R. P. (1980b). ‘‘Resolved-Acceleration Control of

Mechanical Manipulators. IEEE Trans. Automatic Control’’.

[4] Manual book, ‘‘A Beginner’s Guide to PLC’’, version 2.1. Singapore: Omron.2001.

[5] Noel M. Morris„ ‘‘Control Engineering’’ Mc GRAW-HILL Book Company (UK) Limited.

[6] Norman S. Nice „Control System Engineering ‟. Third Edition. California State Polytechnic

University Pomona. John Wiley & Son, Inc., 200

[7] Siemens. „Basic of PLCs‟ STEP 2000 series, Siemens Technical Education Program.