SCADA & PLC based fully automated pneumatic

cutting machine:A test bench for industry and

laboratory
Fahad Durrani1, Muhammad Riaz2, Muhammad Hamza Ahmad1, Sajjad Durrani1, Hazrat Ali1*
1
Deparment of Electrical Engineering, COMSATS Institute of Information Technology Abbottabad
Abbottabad, Pakistan
2
University of Lahore, Lahore, Pakistan
fahaddurrani866@gmail.com, muhammad.riaz@es.uol.edu.pk, hamza6700@live.com, durrani@ciit.net.pk, hazratali@ciit.net.pk
Correspondence: Hazrat Ali, hazratali@ciit.net.pk

Abstract—In this work, we propose to design a fully

automated test bench having pneumatic and small electrical
signals for cutting the material in industry with use of explosive
materials. This test bench can also be used as skill development
platform for professional engineers. The proposed test bench
includes pneumatic controls, arduino, servo motor control and
PLC/SCADA control. This prototype is helpful for engineering
professionals to get hands-on experience on industrial equipment.
This framework includes arduino as controller for servo motor
which pushes the conveyer to push the material forward. DAC is
used for clamper and pusher to hold and push material off the
belt, respectively. The overall system is controlled by Siemens
PLC S7-300 and SCADA (Wincc).

Keywords— cutting, pneumatics, scada, testbench Fig. 1. Experimental Setup of the Test Bench

I. INTRODUCTION SCADA
HMI
In the industry with frequent use of explosive materials,
extraordinary precaution is vital. One of the most important
precautions is to avoid the use of electrical signals. For such PLC unit
industry, this This work presents a prototype design of the (S7300)
Realy control unit
Electro-Pneumatic Control System using PLC S7-300, Electro- outputs Inputs

Pneumatic solenoid valve and double acting cylinders, Arduino

and SCADA (Wincc) as shown in Fig 1, i.e., running prototype Arduino

laboratory test bench. In the following text, we discuss the 5/2way

framework in detail:
solenoid valve

DC
In this framework, we control the sequence of different M clamper
motor
cutter
Double
acting

cylinder. There are two cylinders, the first cylinder is used for
servo motor
cylinde
Proximity r
sensor
clamping i.e., to clamp the piece coming in front of it via a pusher

conveyer. When the first cylinder is activated and clamping Conveyer

COMPRESSER

cylinder comes down and it is detected by the proximity sensor

attached to it, it signals the PLC to perform the operation of
cutting using DC motor on which the blade is mounted. When
cutting operation is completed it gives a signal to third cylinder
which activates the second DAC to push cut product which
comes in front of it. Servo motor are used to control the
position of piece. The length of the product can be adjusted by
changing the arduino codes. We have designed the control
system for these components to run on relays, programmable
logic control (PLC) S7-300 & SCADA [1].
Fig. 2. Block Diagram of Project
II. OPERATION
The block diagram of the prototype test bench is shown in
Fig 2. The SCADA acts as a master control as it triggers other
controllers to perform operations in a controlled manner. The
whole operation control is divided into following sequence:
A. Pneumatic Control
Fig. 3 shows the full pneumatic diagram of the clamper &
pusher double acting cylinder (DAC). Firstly, we press the start
button, which is Normal Open (N/O), and thus, becomes
normal close (N/C) and energizes Relay1. It energizes
“output1” which is N/O becomes N/C, as “Clamper up1”
contact is already N/C which energizes “Clamper down” relay.
In power section the “Clamper down” contact becomes N/C
and starts clamping [2]. This results in the actuation of Y1
cylinder in forward position.
Clamping Pushing
cylinder cylinder

B3 B4
B1 B2

Interup voltage signal

PLC Feedback
to PLC

Signal
Fig 5. Circuit diagram of servo with arduino
to y1
Y1 Y1
C. Servo mechanism
Y1 Y3 Y4
A servo system mainly consists of three basic components:
Signal to y3
x Controlled device,
x Output sensor,
Feedback

Fig 3. Pneumatic Control

x Feedback system.
This is an automatic closed loop control system. Reference
Clamping
energized
Clamping
input signal or command signal is applied to the system, as
cylinder
Position 1
De-energized
cylinder
Position 2 shown in Fig 6. The reference signal is compared with the
output reference signal coming from the output sensor and a
B1 B2 B1 B2 Sensor feedback
for cutting feedback signal produced by the feedback system [4]. If the
reference input signal and the output signal differ, there will
be an input signal to the device. Once the device reaches a
desired value of the output, the difference between reference
input signal and output signal of the signal is logical zero [5].
The servomechanism helps the system to retain a desired
Feedback from
sensor after
Input from PLC after servo
pushing
performed its action
value of the output even if disturbances occur.
Y1 Y2 Y1 Y2

Fig 4. Energization and De-energization of clamper actuator valves

reductiobn
Postion cog

for speed
Gear Box
Clamping operation is shown in Fig 4. It remains clamped
until the blade comes down and cut the object. When the D.C motor Rotation
Output
clamper moves down, the proximity sensor detects it and shaft
sends an input signal to the PLC, turning on a cutter down
Feedback loop
relay when then pushes the blade down to cut the object. The Position
C2 section is then activated. C2 section pushes the object into sensor
bucket. The mechanism is such that the clamper down
proximity becomes N/C and energizes the contact “clamper + Error signal
down”, thus energizing the push forward relay. This actuates A
the actuator 2 which controls the DAC, resulting in energizing Error - Position at input
Y4 and moves the pushers forward [3]. detection signal
Amplifier
Similarly, pushing operation is done. In the reverse
Fig 6. Block diagram of feedback of the servo motor
operation, firstly the cutter goes back, then the pusher goes
back and finally the clamper moves up. D. Working
B. Arduino and Servo Control By pressing the start button servo motor starts through
PLC sends an output signal to the relay so that this relay gets arduino. Servo motor moves the conveyor belt forward in
energized and sends a pulse to arduino control unit to perform order to push the object forward. We are using servo motor
its operation of controlling the movement of conveyer in (4.8V – 6V) having torque of 5.5kg which moves the metal
forward and reverse direction. When start button is pressed the conveyor belt forward and backward. We have calculated the
arduino relay is energized which sends the signal to the revolutions to be 40 rpm. When these revolutions are
arduino board allowing allows the controller to move the completed, the desired length is achieved and the motor moves
servo motor in forward direction. The servo has 97 angles backward. The servo sends a signal to the PLC after
settings, each angle is covered by a delay of 15 milliseconds completing its first revolution. On this signal the PLC
giving a linear movement of the conveyer. Fig 5 shows the activates the actuator and the cylinder moves forward so that
wiring diagram of arduino and servo. the object is clamped for cutting. When clamper moves down,
it comes in front of proximity sensor which then sends a Where
feedback signal to the PLC. This signal activates the cutter [4]. S=Liner displacement (length of conveyer)
PLC activates the first relay to move the blade downward =radius of assumed gear
while the other relay moves the blade in upward direction, as = angle of assumed gear
both relays are connected with opposite polarities. Once the So putting values:
object is cut, the blade moves back to its position on the ⇒105mm = 6.52mm ×
command of PLC. The clamper also moves back to its ⇒ =
position. The PLC then sends a signal to the actuator 2 which .
So = 16.10
moves the pushing cylinder forward and thus, puts the object
Next, we determine the required angle of servo motor by using
in to basket [6, 7].
Eq. (3):
III. MATHEMATICAL MODELLING = ….. (3)
A. Calculation for Servo Motors
The required angle of servo motor (ϑ1) can be determined by
using:
=

6.52
⇒ = × 16.10 = 95.4°
1.1
⇒ = 95.4°
B. Calculations for Cylinders
Servo shaft
r1=1.1mm
N1=7
Conveyer N2=38
Pressure is the amount of force acting per unit area. Where
r2
pressure is represented by “ ” [9]
Fig 7. Conveyer and servo gears shown as circular

We have a gear (as shown in blue color in Fig. 7). We =

consider it to be circular even though it is linear conveyer belt. ⇒F=PA
Both the conveyer and the servo motor gear are equipped with
teeth. We in blue we are considering it angular but in actual it Where
is straight liner conveyer belt we have number of teethes of F=Force in Newton
conveyer and the gear of servo motor, as shown in Fig 7. One A=area of surface on which force is applied
goal is to determine the radius of the assumed angular gear =Pressure created by Appling that force on that area.
(shown in blue color in Fig. 7). This is done by using equation Now we know that area of circle is
(1) (from [8]): A=π×
= = = ….. (1) Where =
=Radius of gear of servo motor So
=Radius of assumed gear which is unknown
= ×
=Number of teeth’s of gear of servo motor 4
= Number of teeth’s assumed gear which is known ⇒A= ×
=Angle on which assumed gear rotates
Now in order to calculate the a single acting pneumatic
= Angle on which gear of servo motor rotate
cylinder with 1034.21 kPa and full bore diameter of 16mm for
=Torque of gear of servo motor
outstroke can be calculated as
= Torque of assumed gear
F = p π d^2 / 4
= (1034.21 kPa ) π (16mm)^2 / 4
Thus, by using the ratio, the radius of the assume gear can be = 206 N
found as: = 0.206 kN
Similarly for in stoke we can calculate it by using the formula
= F = p π (d12 - d22) / 4
where
7 1.1 × 10 d1 = full bore piston diameter (m)
=
38 d2 = piston rod diameter (m)
⇒ = 6.51
Once the radius r2 is determined, the angle of the assumed
gear is calculated by Eq. (2):
S= …..(2)
So putting values cylinder with 1034.21 kPa full bore F = p π (d12 - d22) / 4
diameter of 16mm and rod diameter 1.6 mm can be calculated = (1034.21 kPa ) π [(50mm)2 - (5.0mm)2] / 4
as = 2010 N
F = p π (d12 - d22) / 4 = 2.010 kN
= (1034.21 kPa ) π [(16 mm)2 - (1.6mm)2] / 4 50mm we will have the mass of
= 206 N 2010
=
= 0.206kN 9.8
= 200
Now we know that force is equal to weght but in oder to 50mm cylinder can push mass of 200kg.
calculate the mass that how much force is required to push
specific mass we use formula
= ×
⇒ =
Where
W=weight in Newton
M=mass in kilograms
g=Gravitational acceleration Fig 8. DAC working

So for 16mm we will have the mass of IV. PSEUDOCODE

206
= A. Arduino Pseudocode
9.8
= 21.02
Check if PLC is giving start signal
16mm cylinder can push mass of 21.02kg,
Choose the cutting length
These above calculations was for 16mm but for comparison
Run the servo to move the conveyer
and selection of suitable DOC, we present calculations for
Check if extreme position reached
different diameters
If yes
For 20 mm:
Run servo to move conveyer back
Cylinder with 1034.21 kPa full bore diameter of 20mm and
If no
rod diameter 2.0 mm can be calculated as:
Keep servo moving to get extreme position.
F = p π (d12 - d22) / 4
= (1034.21 kPa ) π [(20mm)2 - (2.0mm)2] / 4 B. PLC Pseudocode
= 322 N
= 0.322kN Check the start button
20mm can push the mass of If pressed
322 Give signal to arduino to move conveyer
=
9.8 Select the length of cutting
= 32 Take feedback from servo when it reaches to extreme
For 32mm: position
Cylinder with 1034.21 kPa full bore diameter of 32 mm and Bring the clamper down.
rod diameter 3.2 mm can be calculated as: Trigger the cutter to cut the material
F = p π (d12 - d22) / 4 Take feedback from cutter when cutting is done
= (1034.21 kPa ) π [(32mm)2 - (3.2mm)2] / 4 Trigger pusher to push material down
= 823 N Bring pusher & cutter back to initial position
= 0.823kN Bring clamper up & again trigger arduino to restart.
32mm we will have the mass of Repeat until stop is pressed.
823
=
9.8
= 83
32mm cylinder can push mass of 83kg.

For 50mm:
Cylinder with 1034.21 kPa full bore diameter of 50mm and
rod diameter 50 mm can be calculated a
 Fig 10. Current Graph showing Servo Motor Running.

Start Stop Output 1

Fig 9. SCADA of Electro-Pneumatic Cutting Machine

V. DISCUSSION Output 1

A. Current Drawn
Fig 10 shows the current drawn by the servo motor while
running. The large spikes show increase in load as motor is Start
Output 1 Relay 1

pushing and small spikes shows the no load current. The rating
of current at no load is 0.005A while on full load it draws Reset
approximately 0.7 A. The motor used has maximum current of
1 A so we operate it in 70% of maximum current.
B. Relay Logic Control
Off delay timer T1 Aurdino
Relay 1
As in Fig. 11, we have two buttons i.e. start & stop. First
arduino is to be triggered through control from the PLC. PLC
provides a 10 second pulse to arduino for moving the
conveyer. For this purpose, CR2 is used with off delay timer Clamper down
T1. Arduino is triggered from normal open contact of T1 to Output 1 Clamper up 1 On delay timer T2

push the material forward. Once the material is pushed

forward, the clamper should come down with some time
delay. For this purpose, the ON delay timer T2 is used, with a
5 sec timer. Proximity sensor is triggered when clamper is Clamperdown prox Clamper down Pulse timer T4
Cutter down

down. The normal open contact with clamper down relay

On delay timer T3

contact is used in all further steps. When clamper is down the

cutter is triggered with time delay for one second and two
seconds using T4 & T3, respectively. After cutting is Clamperdown prox Pusher forward
Clamper down Pulse timer T6
complete, the pusher actuator is triggered to push the material
On delay timer T5

in to the basket. For this, pusher valve is activated with time

delay of 5 sec and 1 sec using T5 and T6, respectively. When
the material is pushed off, the cutter is moved back to its Cutter reverse

initial position using T7 and T8 with time delay of 8 sec and 1 Clamper down prox On delay timer T7 Pulse timer T8
Clamper down

sec, respectively. Then pusher is reversed with timers T9 and

T10 having delay of 12 sec and 4 sec. To bring the clamper up
we have to disconnect the supply to clamper down relay. For Pusher reverse
this purpose, we energize clamper up 1 relay using T11 & T12 Clamper down prox Clamper down
On delay timer T9 Pulse timer T10

with timer values of 2 sec and 10 sec, respectively. Normal

close contact of clamper up 1 relay is used in series at step of
bring clamper down. When clamper up 1 relay is energized, Pusher reverse Clamper up 1
Off delay timer T12
the supply to clamper down relay is disconnected. In the next On delay timer T11

step, we trigger clamper up relay to bring the clamper up. In Clamper up 1

On delay timer T13 Pulse timer T14
Clamper up

this way, all process is completed once. To make it run

continuously, we have to reset all the timers and give pulse to
arduino without pushing the start button again. So reset relay Clamper up Off delay timer T15 On delay timer T16 Pulse timer T17 Reset

is energized using T15, T16 and T17 with check on clamper is

Fig 11. Relay logic diagram
up. Fig 11 shows the relay ladder logic.
 VI. CONCLUSION
In this paper, we presented a prototype for industries with
critical importance of safety hazards under high electrical
signals conditions. For this purpose, we have used pneumatics
system, employing air-operated actuators. The developed
prototype is capable to efficiently cut metals, explosive
materials with desired length. It also provides mathematical
modelling. The prototype can also be used for training of
professionals and provides interface with SCADA and PLC
[10].
REFERENCES
[1] Figliolini, Giorgio; Rea, Pierluigi, “Design and test of pneumatic
systems for production automation”, Proceedings of the Canadian
Engineering Education Association, Aug. 2011
[2] M.Muntaser, A.Mohammed, I.Al-Khawaldeh and. Al-Muzaffar,
"Pneumatic,PLC controlled,automotive gear shifting mechanism", Res.
J. Appl. Sci. Eng. Technol., 2010, vol. 2, no. 3, pp. 245 – 151
[3] G.Venkateswarlu, Jayashree Sahu, Y.Sriya, Sruti Pappala “PLC and
SCADA Based Secured and Sustainable Living”,International Journal of
Advanced Research in Electrical, Electronics and Instrumentation
Engineering, Vol. 4, Issue 4, April 2015
[4] Talbot, Kathleen, "Using Arduino to Design a Myoelectric Prosthetic"
(2014). Honors Theses. 55. Thesis Available at
http://digitalcommons.csbsju.edu/honors_theses/55
[5] J. Chen, X. Zou and F. Wang, "Research and Design of DC Servo Motor
Position Control System Based on LabView," 2010 International
Conference on E-Product E-Service and E-Entertainment, Henan, 2010,
pp. 1-5.
[6] B. Babu, T. Ijyas, Muneer P. and J. Varghese, "Security issues in
SCADA based industrial control systems," 2017 2nd International
Conference on Anti-Cyber Crimes (ICACC), Abha, 2017, pp. 47-51.
[7] Anup Dakre “PLC SCADA based Distribution Monitoring & Control”,
Multidisciplinary Journal of Research in Engineering and Technology
Volume 1, Issue 1 (April 2014) pp. 105 – 110
[8] M. Sreejeth, M. Singh and P. Kumar, "Monitoring, control and power
quality issues of PLC controlled three-phase AC servomotor drive,"
2012 IEEE Fifth Power India Conference, Murthal, 2012, pp. 1-5.
[9] Maulik Timbadiya, Prof. Dimple Khant Development of dsPIC based
HMI for Real Time Monitoring, Controlling and Graphical Analysis of
Industrial AC Drive Global Journal For Research Analysis, Vol: 4,
Issue: 4 April 2015
[10] C Barz et al., “Intelligent traffic control system using PLC” International
Conference on Innovative Ideas in Science, (2016 IOP Conf. Ser.:
Mater. Sci. Eng). 144 012017