CHAPTER 1

INTRODUCTION

1.1 Background
The integration of Programmable Logic Controllers (PLCs) into industrial automation
has ushered in a new era of efficiency, precision, and control. PLCs serve as the
backbone of automation systems, offering unparalleled flexibility and adaptability to
diverse industrial processes. Among the myriad applications of PLCs, motor control
stands out as a cornerstone of industrial automation, with techniques such as Star Delta
and Forward Backward control playing pivotal roles.

These control methods are indispensable for ensuring the smooth and reliable operation
of motors, which are ubiquitous in industrial settings. Motors power everything from
conveyor belts and pumps to robotic arms and CNC machines, driving the productivity
and competitiveness of modern manufacturing facilities. As such, optimizing the
performance and efficiency of motor control systems is paramount for maximizing
productivity, minimizing downtime, and reducing operational costs.

Star Delta and Forward Backward control techniques are specifically designed to
address the unique operational requirements of motors in different scenarios. Whether
it's starting a motor with reduced voltage to minimize inrush current and mechanical
stress (as in Star Delta control) or reversing the direction of rotation with precision and
reliability (as in Forward Backward control), these techniques offer sophisticated
solutions to common challenges in motor control.

1.2 Problem statement

Traditional motor control methods often lack efficiency and flexibility, leading to
suboptimal performance and increased maintenance requirements. Moreover, manual
control of motors can be cumbersome and prone to errors. Hence, there arises a need
for automated control systems that can streamline motor operations while minimizing
human intervention.

1.3 Objective
● To automate a motor control system using plc.
● To minimize use of contactor,push button,timer using plc program.
● To enable remote monitoring and control of motors using plc

1.4 Applications
The applications of Star Delta and Forward Backward control of motors using PLCs
are widespread across various industries. These include but are not limited to:

Manufacturing: Automated conveyor systems, robotic assembly lines, and material

handling equipment.
Oil and Gas: Pumping stations, compressor units, and drilling machinery.
Water Treatment: Pumping and filtration systems for wastewater treatment plants.

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HVAC (Heating, Ventilation, and Air Conditioning): Control of fans, pumps, and
compressors in commercial and residential buildings.

Automotive: Control of conveyor belts, robotic arms, and welding equipment in

automotive assembly plants.

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 CHAPTER 2
LITERATURE REVIEW

A thorough review of existing literature on the topic of motor control using PLCs reveals a rich
body of research and practical applications. Various studies have focused on the implementation
of different control methods, including Star Delta and Forward Backward control, highlighting
their advantages in terms of efficiency, reliability, and safety. Researchers have explored the
theoretical foundations of these control techniques, elucidating the principles governing their
operation

Additionally, case studies and industrial reports provide insights into real-world applications of
PLC-based motor control systems, showcasing their effectiveness in improving productivity and
reducing downtime. Furthermore, advancements in PLC technology, such as integrated
communication protocols and programming capabilities, have expanded the scope of motor
control applications, enabling more sophisticated control algorithms and integration with other
automation systems.

Overall, the literature review underscores the importance of understanding the theoretical
principles, practical implementation, and industrial applications of PLC-based motor control
systems, laying the groundwork for further research and development in this field.

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 CHAPTER 3
RELATED THEORY

2. Basic Principle
The basic principle behind motor control using PLCs lies in harnessing the power of
digital logic to manipulate electrical signals and control the operation of
electromechanical devices, such as motors. At its core, PLC-based motor control operates
on the principle of converting input signals into output actions based on programmed
logic instructions. Here, we delve into the fundamental principles governing this process:

Input-Output Mapping: PLCs interface with the physical world through input and output
modules. Inputs may include sensors, switches, or other devices that detect changes in the
environment or machinery state. These inputs are mapped to corresponding digital or
analog signals within the PLC. Output modules, on the other hand, drive actuators such as
relays, contactors, or motor drives, translating digital signals from the PLC into physical
actions.

Program Execution Cycle: PLCs execute control programs in a cyclical manner, typically
following a scan cycle. During each cycle, the PLC reads input signals, processes them
according to the programmed logic, and updates output signals accordingly. This cyclic
operation ensures continuous monitoring and control of the connected devices, including
motors.

Logic Programming: PLCs employ programming languages such as ladder logic, function
block diagrams, or structured text to define control algorithms. These languages allow
engineers to create logical relationships between input and output signals, implementing
functions such as sequencing, timing, and interlocking. In motor control applications,
logic programming is used to manage motor starting, stopping, speed control, and
direction reversal.

Feedback Control: Feedback mechanisms play a crucial role in motor control to maintain
desired performance and stability. PLCs can receive feedback signals from encoders, limit
switches, or other sensors installed on the motor or associated equipment. This feedback
information is used to adjust control actions dynamically, ensuring precise motor
operation in response to changing conditions or load demands.

Real-Time Processing: PLCs are designed to operate in real-time, meaning they must
respond to input signals and update output signals within specified time constraints. This
real-time processing capability is essential for controlling motors and other time-critical
processes, where delays or inaccuracies can lead to operational inefficiencies or safety
hazards.

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Fault Tolerance: To ensure reliability and safety, PLC-based motor control systems often
incorporate fault detection and recovery mechanisms. These may include built-in

Fig 2 :- Block Diagram of star delta forward reverse motor control using
plc

3.components of motor controller

3.1 Programmable Logic Controllers (PLCs)
PLCs are programmed using specialized software to execute control functions based on
input signals from sensors and switches. These input signals are processed according to
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pre-defined logic instructions, which determine the corresponding output actions to
control actuators such as motor relays. This allows PLCs to regulate various parameters
such as speed, temperature, pressure, and position to achieve desired operational
outcomes.

Fig 4 :- PLC

3.2 Contactor
A contactor is an electrically controlled switch used for switching an electrical
power circuit. A contactor is typically controlled by a circuit which has a much lower
power level than the switched circuit, such as a 24-volt coil electromagnet controlling a
230-volt motor switch

Fig 5 :- Contactor

3.3 push button

Start/Stop Control: Push buttons are used to initiate and terminate motor operations. A
dedicated "Start" push button is pressed to start the motor, while a separate "Stop" push
button is pressed to halt the motor's operation. These push buttons are typically wired to

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the PLC input modules, allowing the PLC to detect their status and execute the
corresponding control actions.

Mode Selection: In systems employing both star delta and forward backward control
methods, push buttons may be utilized for mode selection. For example, a "Mode Select"
push button could be used to toggle between star delta and forward backward control
modes. Pressing the button would signal the PLC to switch between the two control
strategies, enabling flexibility and adaptability in motor operation.

Emergency Stop: In addition to regular start and stop functions, an emergency stop push
button is often incorporated into the control system for safety purposes. This emergency
stop button provides a quick and accessible means of halting motor operation in the event
of an emergency or hazardous situation. When pressed, the emergency stop button sends a
signal to the PLC, causing it to immediately shut down the motor and activate any
necessary safety protocols.

Reset Functionality: In situations where an emergency stop condition has been triggered or
an error has occurred, a reset push button may be used to reset the system and resume
normal operation. This button allows operators to acknowledge and clear fault conditions,
restoring the system to a safe and operable state. Like other push buttons, the reset button
is connected to the PLC input module, enabling the PLC to recognize and respond to user
input.

By incorporating push buttons into the control interface of the PLC-based motor control
system, operators can interact with the system intuitively and efficiently, initiating,
stopping, and adjusting motor operations as needed. Push buttons provide a tactile and
reliable means of human-machine interaction, enhancing the usability, safety, and
functionality of the overall control system.

Fig 6:- Push button

3.4 Three phase -induction motor

1. Operation:

- When three-phase AC power is applied to the stator windings, it produces a rotating

magnetic field that interacts with the rotor.

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 - In a squirrel-cage motor, the rotating magnetic field induces currents in the rotor bars
due to electromagnetic induction. These currents create their own magnetic field, which
interacts with the stator's magnetic field, causing the rotor to rotate in the same direction
as the rotating magnetic field.

- In a wound rotor motor, the rotor windings are connected to external resistors or other
control devices through slip rings. By adjusting the resistance in the rotor circuit, the
speed and torque characteristics of the motor can be controlled.

2. Working Principle:

- The interaction between the rotating magnetic field produced by the stator and the
induced currents in the rotor generates a torque that drives the rotor to rotate. This torque
is proportional to the product of the magnetic flux, the current in the rotor, and the sine of
the angle between them (known as the power factor angle).

- The speed of the motor is determined by the frequency of the applied AC power and the
number of poles in the motor. The synchronous speed of a three-phase induction motor is
given by the formula:

Synchronous Speed (rpm) = (120 * Frequency) / Number of Poles

- However, due to slip (the difference between synchronous speed and actual rotor
speed), the rotor rotates at a speed slightly lower than synchronous speed. The speed of
the motor decreases with increasing load, resulting in a characteristic known as slip.

Fig 7:- Three phase induction motor

3.5 Switched Mode Power Supply (SMPS)

Switched Mode Power Supply (SMPS) is a type of power supply that efficiently converts
electrical power from one form to another using electronic switching devices, such as
transistors or MOSFETs. SMPS offers several advantages over traditional linear power
supplies, including higher efficiency, smaller size, lighter weight, and improved
regulation.

1. AC-to-DC Conversion:

- The first stage of an SMPS involves converting the incoming alternating current (AC)
from the mains power supply into direct current (DC). This is usually achieved using a

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rectifier circuit, which converts the AC voltage into pulsating DC voltage. The rectified
voltage is then filtered using capacitors to smooth out the ripples.

2. DC-to-DC Conversion:

- The filtered DC voltage is then fed into a switching regulator circuit, which performs
the main DC-to-DC conversion. This circuit typically consists of a high-frequency
oscillator, a power switching device (such as a transistor or MOSFET), a transformer,
and a rectifier.

3. Switching Operation:

- The power switching device operates in a high-frequency switching mode, turning

on and off rapidly. This switching action allows the transformer to step up or step down
the voltage levels efficiently.

- During the ON state of the switching device, energy is stored in the transformer's
magnetic field. During the OFF state, this stored energy is transferred to the output
circuit through the secondary winding of the transformer.

Fig 8:- Switched Mode Power Supply (SMPS)

3.11 Advantages of motor control using plc

Motor control using Programmable Logic Controllers (PLCs) offers several advantages
over traditional control methods. Here are some of the key advantages:

1. Flexibility: PLC-based motor control systems are highly flexible and programmable,
allowing for easy customization and adaptation to changing operational requirements.
Engineers can modify control algorithms, adjust parameters, and add new functionalities
without the need for extensive rewiring or hardware changes.

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2. Integration: PLCs can seamlessly integrate with other automation components and
systems, such as sensors, actuators, human-machine interfaces (HMIs), and supervisory
control and data acquisition (SCADA) systems. This enables centralized control, data
exchange, and coordination of multiple devices and processes within a manufacturing or
industrial environment.

3. Reliability: PLCs are designed for robustness and reliability in industrial applications,
with features such as built-in diagnostics, fault tolerance, and redundant hardware
configurations. This ensures continuous operation and minimizes downtime, improving
overall system reliability and uptime.

4. Real-Time Control: PLCs operate in real-time, meaning they can respond to input
signals and execute control actions within specified time constraints. This is critical for
applications requiring precise timing, such as motor control in manufacturing processes
or motion control in robotics.

5. Remote Monitoring and Diagnostics: PLC-based motor control systems can be

remotely monitored and diagnosed using network connectivity and communication
protocols. This allows engineers to troubleshoot issues, monitor performance, and
optimize operations from a central location, reducing the need for on-site maintenance
and enhancing system efficiency.

6. Safety: PLCs support various safety features and protocols to ensure safe operation of
motor control systems. This includes emergency stop functionality, safety interlocks, and
integrated safety PLCs that comply with industry safety standards such as ISO 13849 and
IEC 61508.

7. Energy Efficiency: PLC-based motor control systems can optimize energy usage and
improve efficiency through features such as variable frequency drives (VFDs), which
adjust motor speed based on load demand. This helps reduce energy consumption,
lower operating costs, and minimize environmental impact.

8. Scalability: PLC-based motor control systems are scalable, allowing for easy expansion
and addition of new components or functionalities as needed. This scalability ensures
that the system can grow with the evolving needs of the application or production
facility.

Overall, motor control using PLCs offers enhanced flexibility, integration, reliability,
real-time control, remote monitoring, safety, energy efficiency, and scalability, making it
a preferred choice for industrial automation and control applications.

3.12 Disadvantages motor control using plc

PLC programming and configuration can be complex, requiring specialized skills and
knowledge. Designing and debugging control algorithms may require significant time and
effort, particularly for complex systems or applications with intricate control
requirements.

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Cost: PLC-based motor control systems can be expensive to implement, especially for
small-scale applications or projects with limited budgets. The cost of PLC hardware,
software, programming, and maintenance can add up, making it less feasible for some
organizations or industries.

Dependence on Power Supply: PLCs rely on a stable power supply to operate reliably.
Any interruptions or fluctuations in the power source can affect the performance of the
motor control system, leading to potential downtime or operational issues.

Vulnerability to Cybersecurity Risks: As PLCs become increasingly connected to networks

and the internet for remote monitoring and control, they are vulnerable to cybersecurity
threats such as hacking, malware, and unauthorized access. Without proper security
measures in place, PLC-based motor control systems may be at risk of cyber attacks,
which could compromise safety, reliability, and confidentiality.

Limited Real-Time Performance: While PLCs are capable of real-time control, they may
not offer the same level of performance as dedicated real-time control systems or
hardware. In applications requiring extremely fast response times or high-speed motion
control, PLCs may have limitations that affect their suitability.

Hardware Limitations: PLC hardware has finite processing power and memory capacity,
which may impose limitations on the complexity and scale of motor control tasks that
can be performed. Large-scale systems or applications with high computational
requirements may require additional hardware or specialized controllers to meet
performance demands.

Maintenance and Support: PLC-based motor control systems require regular

maintenance and support to ensure optimal performance and reliability. This includes
tasks such as software updates, firmware upgrades, hardware replacement, and
troubleshooting. Depending on the complexity of the system and availability of skilled
personnel, maintenance and support activities can be time-consuming and costly.

Compatibility Issues: Integrating PLC-based motor control systems with existing

equipment or legacy systems may pose compatibility challenges. Differences in
communication protocols, hardware interfaces, and software platforms may require
additional effort and resources to overcome, potentially leading to delays or
complications during system integration.

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 CHAPTER 4
METHODOLOGY

4.1 Method to be followed to accomplish the Project

Step 1: Collecting the Components Required for this project.

• PLC [1 Unit]
• Three phase induction motor [1 Unit]
• NO push button [3 Unit]
• NC push button [1 Unit]
• Contactor [4 Unit]
• SMPS 24v dc [1 unit]
• Overload relay[1 unit]
• MCCB [1 unit]

Step 2: Assembling the Components

Fig 9:- Circuit Design

Step 3: Connect all the components with the required wires as shown in the above
diagram.

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4.2 Block diagram

fig 10 :block diagram

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 4.3 Construction
The construction of a motor control system employing star delta and forward reverse
control using Programmable Logic Controllers (PLCs) is a complex yet crucial aspect of
industrial automation. This comprehensive guide delves into the intricate details of
constructing such a system, encompassing various components, wiring configurations,
interlocking mechanisms, and PLC programming techniques.

It consist of contactors connected to the PLC which control on and off operation of the
contactor based on the requirement
Basically the contactor are arranged in four arrangement
Forward,reverse,star,delta
1.Forward contactor:
on the input terminal it is connected to RYB phase and output terminal i.e RYB phase is
connected to motor terminal u1,v1,w1 respectively
2.Reverse contactor :
The input terminal is connected to RYB phase similarly as that of the forward contactor
but the on output terminal RYB is connected to output terminal of forward contactor such
that the Y and B phase position is reversed
3.Star contactor :
The upper or input terminal of star contactor is short circuited it RYB phase are
connected together but on lower terminal RYB is connected to the motor terminal
u2v2w2
4 Delta contactor :
Delta contactor primary terminal is connected to forward contractor's secondary terminal
and secondary terminal is connected to w2u2v2 based on forward or reverse it's sequence
change from RYB to RBY
5.MCCB( Molded Case Circuit Breaker):
MCCB stands for Molded Case Circuit Breaker, which is a safety device that protects the
contactor from short circuited mccb provide three 3 phase supply to forward and the
reverse contactor
6.PLC(programmable logic controller):
It control the operation of four contactors , it is connected to auxiliary winding of the
contactor it control on and off operation of contactor based on the program

4.4 Operation of motor controller

Forward star delta operation

1.forward contactor is powered on using PLC hence u1v1w1 is connected to RYB phase
2.at first the w2u2v2 terminal is connected to star contactor.after some time it is turned off
with PLC and hence w2u2v2 get connected to delta contactor thus w2u2v2 get RYB phase
In this way the motor rotates in the forward direction .
Reverse star delta operation
1.reverse contactor is powered on using PLC hence U1V1W1 is connected to RBY
2.At first the w2u2v2 terminal is connected to star contactor the star contactor is turned off
by PLC and it get connected to delta contactor the input terminal of delta contactor is

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connected to output terminal of reverse contactor which is phase altered as result w2u2v2
gets connected to RBY phase and it continue to run on reverse mode

Initially, the input and output devices are connected to the PLC. Upon pressing the start
button, the motor is set to run in the forward direction. The motor can be stopped by
pressing the stop button. To reverse the direction of the motor, the reverse button is
pressed. This entire operation is controlled by the PLC, which can be a model like
DVP-14SS or DVP-14SS2. These PLCs are compact, modular, and come with built-in
inputs/outputs that can be expanded as needed. They support a wide range of
communication protocols and can be used for various applications, including simple
control systems, motion control, and process control.

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 CHAPTER 5
EPILOGUE

5.1 Expected Outcome

1.To control the star delta starter operation using plc.
2.To control operation using a minimum number of push buttons.
3.To operate the motor in both directions using the PLC program.

5.2 Gantt Chart

Given table represents the activities to be performed in each month throughout the
project.

Year 2023-2024 2024

Month 12 01 02 03 04 05 06 07 08

Topic Selection

Literature Review

Proposal Defense

Preliminary Design

Market Survey
andMaterial
Selection

Implementation

Testing and
Modification

Final Report
Submission

Table 1: Gantt Chart

Index:

Work
Completed

Work
Remaining

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 5.3 Estimated Budget
Quantity Cost
S.N. Components (Pcs.) Rate (Rs.) (Rs.) Remark
1 PLC 1 25000 25000
2 NO push button 2 1000 2000
3 NC push button 1 500 500
4 Contactor (32A) 4 10000 50000
5 SMPS (24v) 1 1500 1500

6 Overload relay 1 4000 4000

7 MCCB 1 2000 2000

(15A)
Three phase induction motor Will be
6 - - -
7.5KW (10HP) provided
by collage

Total 85000.00

Table 2: Estimated budget

REFERENCES

1."Programmable Logic Controllers" by Frank D. Petruzella

2. "PLC Programming Using RSLogix 500: Basic Concepts of Ladder Logic

Programming!" by Gary D. Anderson

3. "Industrial Automation and Process Control" by Jon Stenerson, Jerry G. Lathrop,

and Mark A. Hoffman

4. "PLC Programming Basics to Advanced" by Max Klimenko

5. "Practical Industrial Data Communications: Best Practice Techniques" by Deon

Reynders
Websites:
PLCdev (https://www.plcdev.com/): A comprehensive resource for PLC
programming tutorials, articles, and forums.

The Automation Blog (https://theautomationblog.com/)

AutomationDirect (https://www.automationdirect.com/)
Rockwell Automation (https://www.rockwellautomation.com/)
Siemens Automation (https://new.siemens.com/global/en/products/automation.html)

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