PLC based dam shutter control system

Abstract

Dam is a barrier that stops or restricts the flow of water or underground streams. Dam is also
used to collect water or for storage of water which can be evenly distributed among different
locations. The farmers are dependent on seasonal rain and after that bore-well water for their
crops. The dams have tremendous potential for economic up liftment and growth. They can help
in checking floods and famines, generate electricity and reduce water and power shortage,
provide irrigation water to lower areas, provide drinking water in remote areas. Dams are
typically constructed with a drain or similar mechanism to control water levels in an
impoundment for normal maintenance or emergency purposes. A disaster is any event that
causes great harm or damage, serious or sudden misfortune. Dam failures clearly fit this
definition. This dam shutter open/close system using plc will overcome such circumstances, it
will manage the water level of the water reservoir automatically. At two different level, water is
sensed according to which the gate is closed or open. That is when the water level goes above
the threshold mark point level, door opens and it raises buzzer and the solenoid valve opens.
When the water level goes down the door shuts automatically. The input signals are given to the
PLC. The input devices can be push button, level switches, limit switches, sensor etc. The output
of the PLC is given to the final control element. The output elements can be valves, motor,
control relays, alarms, and siren. They control the opening of reservoir for flood control.
Table of Contents

1. Introduction
2. History of Automation
3. Components used
4. Block diagram of system
5. PLC Program
6. Conclusions
1. Introduction

How do engineers work?

Engineering sciences, like the arts, social sciences and natural sciences, are a discrete discipline with
their own language, practices and tools. Of course they also draw on and use principles from other
sciences, in particular mathematics and physics but also social sciences. In turn, many of the
findings in these latter disciplines are based on the results of research carried out in the field of
engineering sciences.

Unlike natural sciences, engineering sciences are not primarily concerned with acquiring information
and discovering the laws of nature but rather with creating technical solutions to satisfy human
needs.

The engineer therefore is always asking "How can I solve this problem?". This leads to a typical
technical approach such as "black-box thinking". Black box thinking means that engineers use
technical systems without needing to know precisely how the individual components and modules
work in detail. All engineers need to know is that the device will deliver a specific output from a
specific input.

Technical system
Input Output

Figure : Black box representation of a technical system

For example, automated machines use electric motors of different sizes and outputs. The machine
designer doesn't need to know exactly how the electric motor works. All he needs to do is select the
right motor using characteristics such as dimensions, torque, speed, current consumption, output,
etc.

In contrast, a situation in which engineers design electric motors themselves is completely different.
In this case they need an in-depth knowledge of the mode of operation and physical fundamentals of
the electric motor and its components.
Another distinctive feature of engineering sciences is the manner in which technical solutions are
represented. Engineers use standardised and therefore internationally understood description tools,
most of which are graphical. The main ones are:
• technical drawings and parts lists,
• circuit diagrams,
• flow charts and programs,
• technical plans and schematic diagrams.

1. Automation technology as a part of engineering sciences

Examples of engineering-related sciences include:

• mechanical engineering,
• electrical engineering,
• production engineering,
• structural engineering,
• and so on.

One point these sciences all have in common is the researching, definition and application of
engineering principles. What differentiates them is the subject matter and the orientation of the
respective discipline.

Automation technology is a crossover discipline that uses knowledge and scientific methods from
numerous other technical sciences. According to DIN 19223, an automatic machine is an artificial
system that makes decisions based on the linking of inputs with the respective states of the system;
these decisions then produce very specific desired outputs.

Three components are needed to realise modern automatic processes:

• sensors to detect the system states,
• actuators to output the control commands,
• controllers for the program flow and to make decisions.
1.1 Key development milestones in the history of automation technology

These days when we hear "automation technology" we immediately think of industrial robots and
computer controllers. In fact, automation technology in craft and industry began much earlier with
the utilisation of the steam engine by James Watt in 1769. For the first time, a machine could replace
manpower or horsepower.

The first steam engines were used to drain water from mines and to drive machine tools. These
applications involved a single steam engine driving a number of machines via a complicated system
of transmission shafts and leather belts (so-called transmission belts) mounted on the ceiling of the
machine hall.

In 1820 the Danish physicist Oersted discovered electromagnetism, in 1834 Thomas Davenport
developed the first direct current motor with commutator (reverser) and received the patent for it
one year later.
Nevertheless, it was not until 1866 that the electric motor became widely used. This was after
Werner von Siemens invented the dynamo that provided a simple way of generating electrical current
in large quantities. The electric motor replaced the steam engine as a driving component.

In 1913 Henry Ford introduced the first assembly line production system for the famous Model T
(Figure 2.1). This resulted in much higher productivity, as production time for a car fell from 750
to just 93 hours. That was the foundation for the series production of cars. This higher productivity
enabled the Ford company to pay its workers a daily wage of 5 dollars for 8 hours of work in 1913.
The price for a Model T fell to around 600 dollars. The automobile became a consumer item for wider
sections of the population and no longer the few well-to-do.

The science behind assembly line production was based on the work of the American Frederick
Winslow Taylor on the division of labour, where production is divided into lots of simple work
steps that even unskilled workers can perform.
 Figure : Assembly line production at Ford (1921)

In 1873 a patent was granted for a fully automatic machine for manufacturing screws that used cam
disks to store the individual program sequences.

In 1837 Joseph Henry invented an electromagnetic switch that was called a relay after the relay
stations where post riders could swap their tired horses for fresh ones.
2. History of Automation
They were initially used for signal amplification in Morse stations. Later they were used for
building electrical controllers. This type of controller, where the relays are hard wired together,
were called hard- wired programmed controllers, a name still used today. Relays could now be used
to master complex control tasks, however the hard wiring meant that programming still took quite a
long time and troubleshooting was time-consuming.

In 1959 Joseph Engelberger presented the prototype for an industrial robot that was used by General
Motors in automobile production from 1961. This robot still had hydraulic drives; it was not until
later that industrial robots were fitted exclusively with electric motors.

In 1968 a team from the American company Allen Bradley under the leadership of Odo Struger
developed the first programmable logic controller (PLC). Now it was possible to simply change a
program without having to rewire lots of relays.

Industrial robots became mainstream in modern industrial production in 1970 and remain so to this
day. Modern production cannot manage without them for the moment at least. Quite the opposite in
fact, their importance is continuously growing. In Germany alone there are well over 100,000 robots,
mostly in the automotive industry and its suppliers.

Effects of automation on people

One of the main reasons for the introduction of automated systems was and remains the desire to be
able to produce goods less expensively than the competition. Automation technology can do this in
several ways:
• Fewer staff are needed for automated production.
• Production can run round the clock, except for a few maintenance interval periods.
• Machines generally make fewer mistakes, which means the quality of the produced products is
consistently high.
• The processing times are shortened, which means that larger quantities can be shipped faster.
• Automation relieves people of boring, physically heavy or hazardous work (humanisation of the
world of employment).

On the other hand, there are also less positive effects associated with automation technology, such as:
 • The loss of jobs, in particular those with a low skill level (one highly qualified service
technician takes the place of 10 unskilled assembly workers).
• The automation of production demands that employees occasionally make decisions, however
the complexity of the system structure is such that they cannot fully decipher their
consequences.
• The expenditure for an automated system of this type increases each individual's responsibility
for the success of the company as a whole.

Fundamentals of electrical engineering

Direct current and alternating current

One of the most important foundations for automation technology is electrical engineering, since
most technical systems need electrical energy both to drive them and to process incoming signals. For
that reason an overview of the most important fundamentals of electrical engineering is provided
below.

A simple electrical circuit consists of a voltage supply, a consuming device and the connecting
cables for transferring the electrical energy. Every electrical circuit is subject to the following
simple rule: "from the generator to the consuming device and back". In physical terms, within the
electrical circuit are negatively charged particles, the electrons that move from the negative terminal
of the voltage supply to the positive terminal via the electrical conductor. This movement of the
charged particles is referred to as electrical current. An electrical current can only flow when the
circuit is closed.

A distinction is made between direct and alternating currents:

• If voltage always flows in one direction in the circuit, this produces a current that also always
flows in one direction. This is a direct current (DC) or a DC circuit.
• With alternating current (AC) or in an AC circuit, the voltage and current change direction and
intensity at specific intervals.
 Direct current Alternating current
Current I

Current I tTime
Time
t

Figure : Direct current and alternating current plotted over time

Figure shows a simple DC circuit consisting of a voltage supply, electrical cables, a control switch and
a consuming device (a bulb in the example).

Figure : DC circuit

Technical direction of current

When the control switch is closed, a current I flows through the consuming device. The electrons
move from the negative terminal to the positive terminal of the voltage supply. Before the existence
of electrons was discovered, the direction of current was defined as flowing from "positive" to
"negative". This definition is still valid in practice today and is called the technical direction of
current.
3. Components used
How a solenoid works
When current flows through an electrical conductor, a magnetic field builds up around it. This
magnetic field grows in size if the current intensity is increased. Magnetic fields exert an attractive
force on workpieces made from iron, nickel or cobalt. This force increases as the magnetic field
grows.

Air-core coil Coil with iron core

and air gap

I
I

Figure : Electric coils with and without an iron core and their magnetic field lines

Structure of a solenoid
A solenoid has the following structure:
• The current-carrying conductor is wound in the shape of a coil (air-cored coil). The overlaying
of the magnetic field lines of all the coil windings (see Figure 3.3) amplifies the magnetic
field.
• An iron core is placed in the coil. When an electric current flows, the iron is additionally
magnetised. This enables a much stronger magnetic field to be generated at the same current
intensity than with an air-cored coil.

Both of these features ensure that a solenoid exerts a strong force on ferrous materials even when the
current intensity is low.
Applications of solenoids
In electropneumatic control systems, solenoids are primarily used to influence the switching position
of valves, relays or contactors. To explain how this happens, we will use the example of a spring-
return directional control valve:
• When an electric current flows through the solenoid coil, the valve piston is actuated.
• When the current flow is interrupted, a spring pushes the valve piston back into its initial
position.

Figure : How a solenoid valve works

How switches work and their structure

Switches are used to facilitate or to interrupt a current flow in an electrical circuit. Depending on
their design, these switches can either be pushbuttons or detenting switches.
• In the case of a pushbutton, the chosen switching position is only maintained for as long as the
pushbutton is actuated. Pushbuttons are used in doorbells, for example.
• In the case of a detenting switch, both switching positions (ON/OFF) are mechanically latched.
Each switching position is maintained until the switch is actuated again. Light switches in
houses are an example of a latching switch in use.

A further classification and selection criterion for switches is their switching status in normal
position (i.e. unactuated).
Normally open contacts
In the case of a normally open contact (or N/O contact), the circuit is interrupted when the
pushbutton is in its normal position. Actuating the pushbutton closes the circuit and supplies the
consuming device with current. When the pushbutton is released, spring force returns it to its
normal position and the circuit is interrupted once more.

1
3
4

2
3

Figure : Sectional view and circuit symbol for an N/O contact

Normally closed contacts

In the case of a normally closed contact (or N/C contact), the circuit is closed by spring force when the
pushbutton is in its normal position. Actuating the pushbutton interrupts the circuit.

1 1

2
3

Figure : Sectional view and circuit symbol for an N/C contact

Changeover switches
The changeover switch combines the functions of an N/C contact and an N/O contact in one device.
They are used to close one circuit and open another one with a single switching operation. Both
circuits are briefly interrupted during the changeover.

2 4 2

1
3
4

Figure : Sectional view and circuit symbol for a changeover switch

Relays and contactors

Applications of relays
Relays are used in electropneumatic control systems to:
1 multiply signals,
2 delay and convert signals,
3 link information,
4 separate the control and main circuits.

They are also used in purely electrical control systems to separate the DC and AC circuits.
 Figure 3.10: Relay

Structure of a relay
A relay is an electromagnetically-actuated switch where the control circuit and the controlled
circuit are electrically separated from each other. It essentially consists of a coil with an iron core
(see (3)(1) in Figure 3.12), an armature as a mechanical actuating element (4), a return spring (2) and
switch contacts (6). When a voltage is applied to the solenoid coil, an electromagnetic field is
generated. This causes the movable armature to move towards the coil core. The armature acts upon
the relay contacts that are either closed or opened, depending on the arrangement. If the flow of
current through the coil is interrupted, a spring returns the armature to its initial position.

2 3

A1

A2

12 14 4 22 24
11 21
1

A1 A2 4 2 1
Coil core (1) Relay coil (3) Insulation (5)
Return spring (2)Armature (4) Contact (6) Figure 3.12: Sectional view and circuit symbol for a
relay

A relay coil can be used to switch one or more contacts. In addition to the relay type described above,
there are also other designs of electromagnetically-actuated switches, for example the remanence
relay, the time relay and the contactor.

Time relays
In the case of time relays, a distinction is made between relays with switch-on delay and relays with
switch- off delay.
In a relay with switch-on delay, the armature switches on with a preset delay td; there is no switch-off
delay. In a relay with switch-off delay, the reverse happens. The contacts switch accordingly (see
Figures 3.13/3.14). The delay time td can be set as required.

a) 27
A1 17
1 2
+24 V A2 18
28
3 17

4 18

A1
K1 1M1
A2

0V

b)
Voltage at the relay coil

Contact

closed
tV

open
a) Representation in the circuit diagram b) Signal behaviour Figure 3.13: Relay with switch-on
delay

Sensors
The purpose of sensors is to acquire information and to forward it in an evaluable format to the
signal processing system. They are found in diverse tasks in technology, with different designs and
operating principles. That is why it is important to categorise them. Sensors can be classified
according to
1 operating principle (optical, inductive, mechanical, fluid, etc.),
2 measured variable (displacement, pressure, distance, temperature, ph value, luminous intensity,
presence of objects, etc.) or
3 output signal (analogue, digital, binary, etc.), to name just a few methods.

The sensors used most frequently in automation technology are those with digital outputs as they are
much more immune to interference than those with analogue outputs. Digital controllers can also use
the signals from these sensors directly without first having to convert them into digital signals by
means of so-called analogue-digital converters as is the case with analogue signals.

The sensors used most frequently in industrial automation are the so-called proximity sensors that
determine the presence (or approach) of a workpiece.

Proximity sensors
Proximity sensors are non-contacting and therefore have no external mechanical actuating force. As a
result they have a long service life and are very reliable. A distinction is made between the following
types of proximity sensor:
• Sensors with mechanical switch contact
o Reed switches
• Sensors with electronic switch output
o Inductive proximity sensors
o Capacitive proximity sensors
o Optical proximity sensors
Magnetic sensors
Reed switches are magnetically-actuated proximity sensors. They consist of two contact blades in a
small glass tube filled with protective gas. The action of a magnet causes the contact between the
two blades to close so that an electrical current can flow (cf. Figure 4.1). In the case of reed switches
that work as N/C contacts, the contact blades are preloaded using small magnets. This preload is
overcome by the then much stronger switching magnet.
Reed switches have a long service life and a short switching time (approx. 0.2 ms). They are
maintenance- free, but must not be used in areas with strong magnetic fields (e.g. in the vicinity of
resistance welders or CAT scanners).

Figure 4: Schematic diagram and circuit symbol for a reed switch (N/O contact)

Electronic sensors
Electronic sensors include inductive, optical and capacitive proximity sensors. They generally have
three electrical connections for:
• supply voltage,
• earth,
• output signal.

In the case of electronic sensors, no movable contact is switched over. Instead the output is either
electrically connected with the supply voltage or to earth (= output voltage 0 V).
When it comes to the polarity of the output signal, there are two different designs of electronic
proximity sensor:
• In the case of positive-switching electronic sensors, the output has a voltage of zero (OFF) when
there is no part within the sensor's response range. The approach of a workpiece results in the
output being switched over (ON) so that supply voltage is applied.
• In the case of negative-switching sensors, supply voltage is applied to the output when there is
no part within the sensor's response range. The approach of a workpiece results in the output
being switched over to a voltage of 0 V.

Inductive proximity sensors

Inductive proximity sensors consist of an electrical resonant circuit (1), a flip-flop (2) and an
amplifier (3) (cf. Figure 4.3). When voltage is applied to the connections, the resonant circuit
generates a (high-frequency) magnetic alternating field that escapes from the front side of the
sensor.

Bringing an electrical conductor into this alternating field "attenuates" the resonant circuit. The
downstream electronic unit, consisting of a flip-flop and amplifier, evaluates the resonant circuit's
behaviour and actuates the output.

Inductive proximity sensors can be used to detect all materials with good electrical conductivity, for
example graphite as well as metals.

Schematic Metal Symbol

diagram
Function circuit diagram

1 2 3

Resonant circuit (1) Flip-flop (2) Amplifier (3)

Figure : Basic representation, function and symbol for an inductive proximity sensor

Capacitive proximity sensors

Capacitive proximity sensors consist of an electrical resistor (R) and a capacitor (C) that together form
an RC resonant circuit as well as an electronic circuit for evaluating the oscillation.

An electrostatic field is generated between the active electrode and the ground electrode of the
capacitor. A stray field forms on the front side of the sensor. When an object is brought into this
stray field, the capacitance of the capacitor changes (cf. Figure ).

The resonant circuit is attenuated and the downstream electronic unit actuates the output.

Capacitive proximity sensors not only respond to materials with a high electrical conductivity (e.g.
metals), but also to all insulators with a high dielectric constant (e.g. plastics, glass, ceramic, liquids
and wood).
 Schematic diagram Symbol

Function circuit diagram

1 2 3

Resonant circuit (1) Flip-flop (2) Amplifier (3)

Figure : Basic representation, function and symbol for a capacitive proximity sensor
Optical proximity sensors
Optical proximity sensors always have a transmitter and a receiver. They use optical (red or infrared
light) and electronic components and modules to detect an object located between the transmitter and
receiver.

Particularly reliable transmitters of red and infrared light are semiconductor light emitting diodes
(LEDs). They are small, robust, inexpensive, reliable, durable and easy to install. Red light has the
advantage that it can be seen with the naked eye when aligning (adjusting) the optical axes of the
proximity sensors.

Photodiodes or phototransistors are used as the receiver component in optical proximity sensors. A
distinction is made between three types of optical proximity sensor:
• through-beam sensors,
• retro-reflective sensors,
• diffuse sensors.

Through-beam sensors
Through-beam sensors have transmitter and receiver units that are set apart. The components are
mounted in such a way that the beam of light emitted by the transmitter hits the receiver (e.g.
phototransistor) directly (cf. Figure 4.6). If an object, workpiece or even a person enters the path
between the transmitter and receiver, the light beam is interrupted and a signal is triggered that
initiates a switching operation at the output (ON/OFF).
Schematic diagram Symbol

Transmitter Receiver

Receiver

Figure : Schematic diagram and circuit symbol for a through-beam sensor

Retro-reflective sensors
In retro-reflective sensors the transmitter and receiver are arranged side-by-side in a housing. The
reflector reflects the light beam from the transmitter to the receiver. It is mounted in such a way that
the light beam emitted by the transmitter impinges almost entirely on the receiver. If an object,
workpiece or even a person enters the path between the transmitter and reflector, the light beam is
interrupted and a signal triggered that initiates a switching operation at the output (ON/OFF).

Schematic diagram Symbol

Receiver
Recei
ver

Transmitt Reflector Reflector

er Transmi
tter

Figure : Schematic diagram and circuit symbol for a retro-reflective sensor

Diffuse sensors
The transmitter and receiver in diffuse sensors are arranged side-by-side in a component. In contrast
to the retro-reflective sensor, a diffuse sensor does not have its own reflector. Instead it uses the
reflective property of the object or workpiece that enters its transmission range. If the light hits a
reflective body, it is redirected to the receiver and the sensor output is switched. This operational
principle means diffuse sensors can only be used if the workpiece or machine part to be detected is
highly reflective (e.g. metallic surfaces, light colours).
Schematic diagram Receiver Symbol

Transmitter Transmitter

Figure : Schematic diagram and circuit symbol for a diffuse sensor

Pressure sensors
Pressure-sensitive sensors come in different designs:
• mechanical pressure switches with binary output signal,
• electronic pressure switches with binary output signal,
• electronic pressure sensors with analogue output signal.

Mechanical pressure switches with binary output signal

In a mechanical pressure switch, the pressure acts on a piston area. If the force exerted by the pressure
exceeds the spring force, the piston moves and actuates the contacts of the switching elements.

>p

2 4

1
1
4
2

Figure : Schematic diagram and circuit symbol for a piston pressure switch
Electronic pressure switches with binary output signal
Typical examples of electronic pressure switches with binary output signal are diaphragm pressure
switches that switch the output electronically instead of actuating a contact mechanically. Pressure or
force-sensitive sensors are attached to a diaphragm for this purpose. The sensor signal is evaluated by
an electronic circuit. As soon as the pressure exceeds a previously defined value, the output
switches.

Figure : Electronic pressure switch and circuit symbol

Fundamentals of pneumatics

The term pneumatics comes from the Greek work "pneuma", meaning wind or breath. It refers to the
use of compressed air or systems driven by compressed air in an engineering application. A modern
pneumatic system in automation technology consists of subsystems for:
• generating and providing the compressed air (compressors, radiators, filters),
• distributing the compressed air (ducts, pneumatic tubing, coupling pieces),
• controlling the compressed air (pressure regulators, directional control valves, stop valves),
• performing work using the compressed air (cylinders, rotary drives).

Compressed air is most often used to perform mechanical work, i.e. to carry out movements and to
generate high forces.
Pneumatic drives serve to convert the energy stored in the compressed air into kinetic energy.

For the most part, cylinders are used as pneumatic drives. They have a sturdy design, are easily
installed, offer a favourable price/performance ratio and come in a wide choice of variants. These
advantages have opened up a wide range of applications for pneumatics in modern engineering. The
following table outlines further advantages.

Characteristics Advantages of pneumatics

Quantity Air is available virtually everywhere in unlimited quantities.
Transport Air can be very easily transported over large distances in ducts.
Storage ability Compressed air can be stored in a reservoir and supplied from there. The
reservoir (bottle) can also be transportable.
Temperature Compressed air is virtually insensitive to temperature fluctuations. This
guarantees reliable operation even under extreme conditions.
Safety Compressed air does not represent a hazard in terms of fire or explosion.
Cleanliness Leaks of unlubricated compressed air do not cause environmental
pollution.
Setup The operating elements have a simple setup, therefore they are
inexpensive.
Speed Compressed air is a fast working medium. It facilitates high piston speeds
and fast switching times.
Overload protection Pneumatic tools and operating elements can be loaded until they finally
become inoperative and are therefore overload-proof.

Physical fundamentals
Air is a gaseous mixture with the following composition:
• approx. 78% nitrogen
• approx. 21% oxygen

It also contains traces of water vapour, carbon dioxide, argon, hydrogen, neon, helium, krypton and
xenon.
To help you understand the laws of air, the physical variables that occur in this context are listed
below. All specifications are in the "International System of Units", or SI for short.

Basic units

Variable Symbol Units

Length l Metre (m)
Mass m Kilogramme (kg)
Time t Second (s)
Temperature T Kelvin (K, 0 °C = 273.15
K)

Derived units

Variable Symbol Units

Force F Newton (N), 1 N = 1 kg •
m/s2
Surface A Square metre (m2)
Volume V Cubic metre (m3)
Volumetric flow rate qV (m3/s)
Pressure p Pascal (Pa)
1 Pa = 1 N/m2
1 bar = 105 Pa

Newton's law
Force = mass • acceleration F = m • a
(in the case of free fall, a is replaced by gravitational acceleration g = 9.81 m/s2)

Pressure
1 Pa corresponds to the pressure exerted by a vertical force of 1 N on an area of 1 m2.
The pressure on the earth's surface is referred to as atmospheric pressure (pamb). This pressure is also
called reference pressure. The range above this pressure is called the excess pressure range (pe > 0),
while the range below is called the vacuum range (pe < 0). The atmospheric pressure differential pe is
calculated according to the formula:
pe = pabs – pamb

This is illustrated in the following diagram:

kPa (bar)

pamb pamb
pe, 1 >0 1

~ 100 kPa
pamb
2 (1 bar)
0

pabs = 0 kPa

Air pressure
Atmospheric pressure is not constant; its value changes depending on the geographical location and
the weather.

Absolute pressure pabs is the value referred to as zero pressure (vacuum). It is equal to the sum of the
atmospheric pressure and excess pressure or vacuum. The pressure gauges used most frequently in
practice are those that display only the excess pressure pe. The absolute pressure value pabs is
approximately 100 kPa (1 bar) higher.

It is usual in pneumatics to refer all specifications relating to air quantities to the so-called normal
condition. The normal condition to DIN 1343 is the condition of a solid, liquid or gaseous material
defined by means of standard temperature and standard pressure.

• Standard temperature Tn = 273.15 K, tn = 0 °C

• Standard pressure pn = 101325 Pa = 1.01325 bar

Programmable logic controllers (PLCs)

General information
These days complex control tasks are mainly handled using programmable logic controllers (PLCs).
With this type of controller, the program is not realised through the linking of individual relays but
rather using appropriate software. PLCs mainly process binary signals.

Their advantages over contact controllers or hard-wired programmed controllers are:

• just a few logic blocks in the software instead of numerous relays,
• less wiring,
• more flexible when it comes to changing the programs quickly and effectively,
• faults are easier to find,
• much more cost-effective.

The MecLab® learning system uses a PLC simulated in the FluidSIM® software instead of an actual PLC.
The programming of this PLC is essentially the same as for a standard PLC such as the Siemens
"LOGO!" controller shown in Figure , for example.
24V I1 I2 I3 I4 I5 I6

0V Q1 Q2 Q3 Q4 Q5 Q6
4. Block diagram of system

Logic symbols in the FluidSIM® control software

Using controllers in an application only makes sense if their sequences happen at precisely the right
time, at the exact position and in the correct order. This calls not only for reliable hardware, but also
software that enables complex technical sequences to be both planned and controlled and that has a
user interface conforming to international standards. The FluidSIM® software meets these
requirements.
FluidSIM® offers three options for developing a control system:
• pneumatic circuits,
• electrical circuits,
• logic circuits.
All of these circuit types can be combined together and the simulation mode enables controller
functions to be put to the test before they are realised on the actual module. This advance testing of
the developed solution on the computer means that damage to the technical system can be avoided.
The following table provides an overview of the most important logic symbols available in
FluidSIM®.

Symbol Designation Function

&AND Switches the output to 1 when all inputs are 1. Unassigned
inputs are always 1.
>
-1OR Switches the output to 1 when at least one input is 1.
Unassigned inputs are always 0.
1 NOT Inverts the input.

& NOT AND (NAND) Switches the input to 0 when all inputs are 1. Unassigned
inputs are always 1.
RS Latching element Switches the input to 1 when the upper input is set to 1. The
output is only reset to 0 when the lower input is set to 1.
Switch-on/off delay When the input is set to 1, the output is set to 1 after the first
set time has elapsed and reset to 0 after the second set time
3 has elapsed.
 Symbol Designation Function
Time delay clock The output is set to 1 after the switch-on time has elapsed
and reset to 0 after the switch-off time has elapsed. The
10 process can be repeated.
M Label The output assumes the value of the input. This is necessary
because some logic blocks cannot be connected with the
output of another logic block.
Counter Counts how often the value 1 was applied at the middle
+/- input. The output is set to 1 after a preset number of
0 (5) counting pulses is reached. The direction of counting
(forwards/backwards) can be set using the lower input and
the counter can be reset using the upper input.

Table : Logic symbols in FluidSIM® (continued)

Programming a logic control system using a PLC

Example 1: Self-latching loop

Figure 9.2 shows a circuit with double-acting cylinder and 4/2-way single solenoid valve. A PLC
program is to be created for it that enables the piston rod to advance when a pushbutton T1 is pressed.
The piston rod should retract when the forward end position has been reached. The forward end
position is detected via proximity sensor 1S1.
Figure : Pneumatic circuit diagram with solenoid valve and proximity sensor
 Figure : PLC program for Figure 9.2

Figure 9.3 shows the accompanying PLC program. The pushbutton T1 is connected to the input I1 of
the PLC. This activates a latching element that switches on the valve solenoid 1M1 connected to the
output Q1 of the PLC.

When the piston of the cylinder 1A (see Figure 9.2) reaches the forward end position, the sensor 1S1
connected to the input I2 of the PLC is activated. The latching element and thus also the output Q1 are
reset. The valve returns to its normal position and the cylinder piston rod retracts.

Components:
PLC
Level Sensors
Push buttons
Led Lamps
Relay
DC motor
SYSTEM DEVELOPMENT

In this system we developed the overall method in manyways. First one is that the targeted
devices can be controlled by PLC (Programmable Logic Controller).

IMPLEMENTATION OF PROPOSED SYSTEM

In this section the prototype that we have developed to implement the proposed system has
beenexplained. There are various components we used to implement this system. The whole
system is divided into various sections and each are explained separately.
A. Programmable Logic Controller(PLC)
This is heart of our proposed system which controls the entire operation of system. This compact
Micrologix 1400 PLC, economical programmable controllers offer several I/O configurations. In
this PLC , there are 20 input and 12 output are available .

this programmable logic control device of inputs are connected in 5 micro switch and this 5
micro switch are connected toward the SMPS(switch mode power supply ) SMPS is connected
in our system because this PLC are required in 24volt dc.
The micrologix 1400 PLC of output is connected the DC motor. This motor are connected
toward relay driver because motor rotation in two direction. The two relay are work as forward
direction. "ladderlogic", which strongly resembles a schemati diagram of relay logic. Ladder
logic is a programming languages, that represents a program by a graphical diagram based on
the circuit diagrams of relay logic hardware.

It is primarily used to develop software for programmable logic controllers (PLCs) used in
industrial control applications.
5. PLC PROGRAM:
SCADA

SCADA stands for supervisory control and data acquisition. The software used in SCADA [3] is
wonderware Intouch 9.5. It is used for collecting the data from switches and devices located at
remote site and display on computer at control site for monitoring and controlling.
In our project we are using SCADA for graphical representation of motor control operation
during opening and closing of gates. This entire process will be recorded in data login table at
control room.
Data login table basically consist of time, date, status of variable processes and devices.
6. Conclusions

In this module, Ethernet port provides web server capability and protocol support for DNP3
protocol support. Built-in LCD with backlight lets you view controller and /O status and built-in
LCD provides simple interface for messages.
Bit/integer monitoring and manipulation. Expands application capabilities through support for
as many as seven 1762 micrologix Expansion I/O modules with 256 discrete I/O as many as six
embedded 100 kHz high-speed counters.
In this PLC there are two serial ports with DF1, DH-485, Modbus RTU, DNP3 and ASCII
protocol support 10 KB words in user program memory with 10KB words in user data memory
up to 128KB for data logging and 64KB for recipe.