Paper ID #14543

MAKER: Programmable Logic Control (PLC)-Based Automated System for

Water-Level Control for Teaching Pneumatics and Hydraulics
Prof. Javaid S. Siddiqi, Lone Star College
PROFESSOR AT LONE STAR COLLEGE. TEACHING AND RESEARCCH AT ENERGY AND MAN-
UFACTURING INSTITUTE OF LONE STAR COLLEGE SYSTEMS. RESEARCH AND DEVELOP-
MENT IN THE FIELD OF APPLIED TECHNOLOGY.DESIGN AND IMPLEMENTED COURSES
FOR THE STUDENTS.
Dr. Sheng-Jen ”Tony” Hsieh, Texas A&M University
Dr. Sheng-Jen (”Tony”) Hsieh is a Professor in the Dwight Look College of Engineering at Texas A&M
University. He holds a joint appointment with the Department of Engineering Technology and the De-
partment of Mechanical Engineering. His research interests include engineering education, cognitive
task analysis, automation, robotics and control, intelligent manufacturing system design, and micro/nano
manufacturing. He is also the Director of the Rockwell Automation laboratory at Texas A&M University,
a state-of-the-art facility for education and research in the areas of automation, control, and automated
system integration.

American
c Society for Engineering Education, 2016
 MAKER: Programmable Logic Control (PLC) Based
Automated System for Water-Level Control
for Teaching Pneumatics and Hydraulics

Abstract

This paper describes the design, construction, and evaluation of a learning module on
pneumatics, hydraulics, and actuators that incorporate a PLC controlled automated system for
water level control. The module was developed to address a knowledge gap between two
courses—one on pneumatics/hydraulics and another on automated control—and employs cost-
effective hardware and software tools to provide interesting hands-on experiences for college
students. The automated control system consists of level sensors, relays, water tank, and a
submersible pump along with a motor, DC power supply and programmable logic controller
(PLC) to automate the pumping of water. The system is used to show students how to interface
I/O devices with a programmable logic controller (PLC) in the context of designing and building
a system to control the water level in an overhead storage tank. The system also controls the
pump motor on/off switch, thus saving energy. The system is portable and can also be used for
K-12 outreach activities. Evaluation results suggest that students learned the subjects well and
that the hands on experience helped them to better understand how pneumatic and hydraulic
components are used within industrial automated systems.

Motivation

The introduction of PLC has revolutionized the manufacturing industry and automation as a
whole. For complex manufacturing PLCs are used widely. Our educators are reluctant to
introduce PLC related Courses in the industry because of lack of teachers, not enough Lab
equipment or not having enough funds for this emerging technology. There are different ways of
introducing this Course (PLC) one way is to make it web based teaching which can be accessible
from anywhere. A Model building of PLC in an existing Course, Also it can be done in hybrid
Course and Labs can be done in person at schools. To make our students to succeed we have to
use intelligent tutoring system technology and games to teach about programmable language for
PLC. Research has established Hands on education approach is most effective there fore PLC lab
oriented activities will be more exciting to Automation students.

Integration of PLC Project

A PLC project to develop a system for water level control was added to an existing two-year
college course on hydraulics and pneumatics systems in the manufacturing and energy sectors.
The system will automate the process by placing two sensors (lower level and upper level) into a
tank and integrate them with a PLC so that measurements of the water levels and be periodically
taken and feedback will be provided to the system, which will control the motor automatically
and eventually control the pump. This system eliminates the need for people to fill the water
tanks and check for overflow daily. Problems such as water overflow, empty tank, and motor
overheating due to continuous usage can be avoided.

The syllabus with the added project is shown below.

 Week
Activities and Assignments Objectives and Details
Number
Meet and greet students. Introduction
1 Class introduction
of students and instructor
Introduction to Hydraulics and Pneumatics. Define the terms fluid power,
(Lab) hydraulic System and Pneumatics..
Explain the functions of fluid power
Different types of fluid power systems. systems.
(Lab) Identify the basic structure of fluid
power systems.
Identify and explain the design and
operation of the six basic machines.
2 Basic physical principles. (Lab)
Explain and apply different basic
electrical circuits.
Importance of standards and symbols
Fluid power standards and symbols. (Lab) in the fluid industry.
Test1 Identify groups that regulate fluid
power industry.
Importance of safety and health,
define safety rules and regulations.
3 Safety and health (Lab). How good and bad working
environment can influence the safety
and health.
To introduce different properties of
Study of hydraulic fluid
hydraulic fluid.

Sources of hydraulic power. (Lab) Introduce pumps and compressors and

its application in providing Kinetic
energy to the fluid.
Explain the factors that must be
Fluid storage and distribution (Lab) considered when establishing the size
4
Test 2 of a reservoir. Contamination and its
effects.
Importance and application of
Application of Actuators. lab
actuators in fluid power.
Explain the effect of temperature,
Lecture on how to control the system with
pressure variations have on the
the help of different valves. (Lab)
operation of different valves.
Explain the four basic functions of
Introduction to accumulators (Lab)
5 accumulators.
Mid Term
 Week
Activities and Assignments Objectives and Details
Number
Study different types of heat
How to perform conditioning. (Lab)
exchangers.
Study of different circuits and systems. Learn about advanced hydraulic
(Lab) circuits.
Describe the characteristics of
Introduction to Pneumatics. (Lab)
compressed air.
Study of different types of
6 Sources of pneumatic Power. (Lab)
compressors
To introduce different methods used in
Conditioning of Air. (Lab)
conditioning of Air
Introduction of pneumatic motors and How to apply linear and rotary motion
cylinders in pneumatic systems.
7 Controlling a pneumatic. Lab system Introduce different types of valves.
Explain the design and operation of
Introduction of pneumatic circuits. (Lab)
motion control circuits.
Hydraulics and Pneumatics working
8 Practical application of different circuits
circuits
PLC PROJECT:
To elevate and solidify learning
Develop a PLC based program to process of students in the field of
9 control the pump Flow rate to keep a Hydraulics and Pneumatic systems
fixed upper level and fixed lower level in by incorporating PLC controlled
a water tank all the time, and hence System
controlling the pump motor.
Final test Comprehensive test

PLC Project Scope

The PLC project covered the following topics:

1. Introduction to PLC
2. Relays
3. Contactors
4. Starters
5. Programmable logic controllers and programming
6. Ladder and Line diagrams
7. Industrial interfacing
8. Motor control
9. Pumps
10. Level sensors
Discussion of PLC benefits

Smaller physical size than hard-wired solutions.

• Easier and faster to make changes.

• PLC has integrated diagnostics and override functions.
• Diagnostics are centrally available.
• Applications can be immediately documented.
• Applications can be duplicated faster and less expensively.
• Cost effective for controlling complex systems.
• Flexible and can be reapplied to control other systems quickly.
• Computational abilities allow more sophisticated control.
• Trouble shooting aids make programming easier and reduce downtime.

Component Used

The Water Level Controller has the following main components, which can be acquired from
LabVolt:.
• Two sensors
• DC Power Source
• Full-wave rectifier
• PLC
• Centrifugal Submersible Pump
• Relay
• Motor
• Water tank

Project System platform

For students this system is multi-purpose, flexible, and allows them to do different lab- job
sheets with the same components. Several groups of students can integrate these platforms to
form larger PLC controlled systems.

The information in Table 1 will assist financial decision makers to purchase this system.

Table 1. Items for project system platform.

Item Price
1 Allen Bradley Micrologix 10000 plc $ 1000
2 PLC software $0
3 DC power supply $250
4 Relays $20
5 Set of sensors $40
6 Set of water pump and motor with tank $550
Total $1860
The system platform can also be used with K-12 students. A group of middle and high school
students from underserved areas were invited to interact with hands - on learning experience
“Water level Control By PLC”. The student learning outcomes were 80 percent positive and
program learning outcomes were assessed and forecasted to buy more trainers so that smaller
groups can be formed, allowing individual students to experience this activity and write program
and run the systems.

The ladder diagram above includes the following steps:

1- Input 0 energizes the pump when activated
2- Output 2 is ON when motor energized
 3- A 5 sec delay is timing 5 second delay after motor energized to indicate required time
motor has been on
4- Output 3 indicates the end of 5 second delay
The most common applied control systems today are PLC which will precisely control fluid level
in a tanks. PLC or programmable controller is a digital computer used for automation in
electromechanical processes, such as control of machinery on factory assembly lines, or lighting
fixtures. PLCs are used in many industries and machines. Unlike general-purpose the subject
invention pertains to facilitating communication between industrial computers, the PLC is
designed for multiple inputs and output arrangements, extended temperature ranges, Pressure,
flow rate, level control immunity to electrical noise, and resistance to vibration and impact.
Programs to control machine operation are typically stored in battery-backed or non-volatile
memory. 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.

Evaluation

The student evaluation is based on building and implementing a ladder diagram to control the
water level. The students were assigned this project in the beginning of the hydraulic and
pneumatic course. Pre- and post-tests suggested that they improved their knowledge by 90
percent.

Pretest Programmable Logic Controllers

Water level control
Unit 1, Task 1
1. What is a PLC?
(Digital electronic apparatus with a programmable memory.)
2. What are the four main components of a PLC?
(Input section, CPU section, Programming Device, Output section)
3. What is a discrete device?
(Two states, On and Off)
4. What is a pulse-generating device?
(Shaft Encoder)
5. What term is used to describe the CPU in a PLC?
(Brain)
6. What is the difference between a communication port and a programming port on a PLC?
(Programming Device-Programming Port, Other PLC-Communication Port)
7. What is an Uninterruptible Power Supply?
(UPS) (Clean AC Power source)

Post-Test Programmable Logic Controllers

Water level control
Unit 1, Task 1
1. What are the components required for water level control system.
(Pump, hoses, motor PLC, and a tank)
2. What is the typical maximum amperage for switching with the output section of a PLC?
(Typically 10A max)
 3. What are the three main categories of loads controlled by a PLC?
(Discrete, Analog, Pulse)
4. What are the two main parts of a PLC programming device?
(Display and Keyboard)
5. What are the four functions of a PLC programming device?
(Program Entry, Documentation, Run, Monitoring)
6. What are two main classifications of Pumps?
(Positive displacement and Non-Positive displacement
7. How can we increase the flow rate of a pump

The work presented in this research paper highlights the level control of water in the tank. With
this implemented system pump motor is switched on and off with the feedback system from the
level sensors. By doing so the water wastage is eliminated and more energy efficient system is
designed. All control signals pass through and processed by the microcontroller. Tests were
conducted to ensure the functionality of water level control.

Future Activities

The future recommendations are, application of PLC in the control of Pneumatic Actuators
(Cylinder speed control for variable loads) and then studying the Hydraulic and Pneumatic
Systems simultaneously controlled by PLC.

Acknowledgements

This material is based upon work supported by the Research Experiences for Teachers Program
under National Science Foundation under Grant No. 1300779. Any opinions, findings, and
conclusions or recommendations expressed in this material are those of the author(s) and do not
necessarily reflect the views of the National Science Foundation.

References

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Automated Water Level Sensing and Controlling: Design and Implementation Issue’. Proceedings of the World
Congress on Engineering and Computer Science, pp 220- 224.
4. Venkata Naga Rohit Gunturi (2013), ‘Micro Controller Based Automatic Plant Irrigation System’, International
Journal of Advancements in Research & Technology, Vol. 2, No. 4, pp. 2278-7763
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Proceedings of the 19th international pump users symposium. pp 1-8.
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International Journal of Scientific and Research Publications, Vol. 3, No.3, pp 1-4.