International Conference on Energy, Communication, Data Analytics and Soft Computing (ICECDS-2017)
PLC based Automation of Test Rig for Brake Actuators
Malakanagouda B B
Computer Integrated Manufacturing
R V College of engineering
Bengaluru, Karnataka
malakanagouda024@gmail.com
Abstract— During the past decennium, number of industrial
automations have been developed based on Electro pneumatics.
This paper represents the application of PLC (Programmable
logical controller) and SCADA (Supervisory Control and Data
Acquisition) system in the Industrial automation. The
conventional method of testing machine with pneumatic setup is
automated with the electro pneumatic system and PLC based
system. The automation of testing machine with the help of
various sensors and control devices with high accuracy modules
decreases the errors in the results. The automation of testing
machine involves the Simulation with Fluidsim, design and
development of Electro pneumatic circuit as well as development
of PLC logic with SCADA control system.
Keywords—Programmable Logic Controller(PLC) ;
Supervisory Control And Data Acquisition(SCADA); Electro
pneumatic,Fluidsim.
I. INTRODUCTION
Industrial automation is becoming global trend in
manufacturing. Industries without automation unable to
withstand in the global market. In the recent years the
automation market is prospering as compared to earlier
because of competitive market. The recent survey found that
the industrial automation projected to reach USD 153.30
Billion by 2022, at a CAGR of 4.88% during the forecast
period. Most of the industries switched to industrial
automation to make the products cost effective and reach the
demand of the customers.
The product validation is also one of the important process in
the industry. In this process cycle time is more and accuracy
of test results are less due to manual method of product
validation. By implementation of automation in this process
enhance the benefits as compared to manual method of
product validation.
The automation can be done using LabVIEW, PLC, Python
etc. In most of the application the PLC is used because of its
reliability, ease of uses and cost effective as compared to other
type of automation. Hence in this project the PLC and
SCADA based automation is used in the products validation
which in turn results in the advantages as compared to manual
method which in turn increases the productivity as well as
safety. This project is consecrated to the use of automatic
978-1-5386-1887-5/17/$31.00 ©2017 IEEE
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Harisha.S.K
Computer Integrated Manufacturing
R V College of engineering
Bengaluru, Karnataka
harishask@rvce.edu.in
electro pneumatic control system in testing system; the control
system will act as a major function in control on all electro
pneumatic parts of the project. This project is about the design
and development of an automated testing system. EPV, EP
valves are used to control the flow of pneumatic line. Sensors
are used to send the data to the control system.
A. Literature review
PLC and similar methods are used in various researchers all
over the world. Shantanu L.Kulkarni et al (2013) [1] used PLC
in the food industry in order to reduce the beverage filling
time as well as high accuracy with a standard filling of bottles.
Also, it gives safety for operators. He used SCADA and PID
controller which will control the entire process Also it leads to
cost reduction and productivity increases. This system deals
with the present value of the timer. The value is switched ON
for that specific period of time and the filling is finished. This
system is the best use of mechanization exceptionally for large
scale manufacturing businesses as different kind of part
handled in brief timeframe that builds creation. This uses the
different height of bottle for filling operation.
Reema Patel et al(2014) [2] utilized the Programmable
Logical control (PLC) and Supervisory control and data
acquisition (SCADA) for a process for automated cooking
which will cook the food as per selection in SCADA screen.
Initially, need to provide all specifications related to the
particular item. Then a selection of list in the SCADA screen
as per requirement like how many persons, which food. After
that machine automatically cooks as per selection then it is
ready to eat. This machine consumes less time, this machine
has the capacity to store a number of recipes in it, So that
different type of recipes can be prepared from the same. So
this machine gives the taste as per requirement.
Bhupendra Singh et Al (2015) [3] by using PLC molding of
bricks can be done by bricks molding mechanism. In this
molding mechanism used PLC based hydraulic compression
method used this molding machine has three sets of brick
molds which are 120 degrees apart from each other. So in this
way pressing will take place. In this PLC is important which
will provide more safety to the plant operators same time
increases the productivity. Pravin choogle is (2012) [4], PLC
based automation of drilling machine with conveyor assembly
mainly it provides the safety in the working area. It involves
 International Conference on Energy, Communication, Data Analytics and Soft Computing (ICECDS-2017)

the control of motor and conveyor system which is controlled used to control the process. Testing is controlled by using
through PLC which reduces the time required to drilling various methods using EPV, pressure sensors, solenoid valve,
operations manually compared with automation. PLC, LVDT, Load sensors.
Alhade A.Algitta et al (2015) [5], by use of programmable
logic control in the automation industry to packing process. It
involves the total integration of PLC, conveyor system, Understanding of existing
sensors which will give automated packing system. By this test specifications
packing time reduces as well as packing standard increases.
B. Problem defination Development of pneumatic
circuit for test rig
In the manufacturing industries the validation of the products
after final stage is most important process.In this process due
to usage of conventional method cycle time increases which in Simulation of pneumatic line
turn comes down the productivity. The development of PLC through Fluidsim
based automated test rig reduces the above problems and
No
implementation of SCADA screen helps in traceability, virtual
appearance of testing, test report generation etc. The PLC
Is Simulation
based system automation is more ease of usage and reliability is matching
as compared to the other systems.
Yes
C. Objectives
The objective of the thesis is to develop a fully automated Development of manifold for
model of testing system. This will reduce the time Pneumatic circuit to modular
the system modular the system
consumption between the operations while sequence of
testing. Less numbers of man powers is required and hence
increases the speed and efficiency of production. Development of electro
¾ Design a pneumatic circuit to control the brake actuator pneumatic circuit to make the
test rig system automatic
¾ Simulation of the pneumatic circuit by using Fluidsim.
¾ The design of Mechanical components of the brake
Design a PLC and SCADA
actuator test rig. based control system to test
¾ Fabricate a compact manifold to make it modular. the brake actuator.
¾ Develop electro-pneumatic circuit to make the system
automatic.
Test the real-time brake
¾ Design a PLC and SCADA based control system to test actuator system and validating
the brake actuator.
¾ Test the real-time brake actuator system and validating
with an alternate method. Comparison of old testing and
automation testing machine

Figure 1: Flow chart of methodology

II. METHODOLOGY
This paper is a complete application of PLC and SCADA
automation with electro pneumatic circuit. The testing
processes commanded by PLC and supervised by using
SCADA. PLC and SCADA are the significant constituents of
the testing system. The entire system is controlled according
to the ladder logic programmed PLC and SCADA is used to
supervised the testing sequence in the system.
New technologies are required that will reduce testing time,
increase accuracy and minimize downtime in high-speed
testing environments. The various process of this system is
controlled by PLC. PLC is the heart of the system and the
system is controlled according to the programmed PLC. The
automatic testing system based on PLC control system has
advantages of smooth operation, low accident rate. So In order
to improve the production efficiency and the testing accuracy,
it is quite necessary to apply PLC (Programmable Logical
Controller) in the automatic testing system. Ladder logic is
A. Study of process parameters involved in automation of
test rig
While design and automation of test rig many parameters are
to be considered based on test specification standard while
testing we have to maintain timings and cycle time properly.
For proper testing of test rig many constraints also required ,
for example, the accuracy of the pressure sensor is minimum
0.25 % also same time the solenoid valves also 0 % leak proof
then the only system runs properly if accuracy is less than
required results what we are getting is change from original
valves what required to meet as per test specification also
other sensors Load cell and LVDT are to be chosen as per
requirement .Also as per operating pressure is 16 bars need to
choose the solenoid valves, EPV, Pressure sensors.

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 International Conference on Energy, Communication, Data Analytics and Soft Computing (ICECDS-2017)

B. Design of mechanical set up in 3D using creo 3.0 easily by using drag and drop. You only have to place the
The design of mechanical setup required to test the brake items in the circuit as you want to view them and build the
actuators needs a lot of things to be considered because testing circuit intuitively. Simple and effective. Fluidsim offers an
of brake actuator design should match for fixing in it. Also, intuitive circuit diagram editor with detailed descriptions of all
many actuators with different sizes can be easily fixed. Also, components, sectional view animations, component photos
proper provisions for the fixing sensors to get data easily and video sequences. By this way, Fluidsim is perfect for use
without damage to the sensors. For holding the actuator, we in lessons and for the preparation thereof and as a self-study
need to be providing clamping cylinders with the operating program
pressure 3 bars. The clamping and decamping should be
operated by SCADA automatically.
C. Design of pneumatic circuit
Based on required parameters to test the performance of the
brake actuator pneumatic circuit is to be developed based on
the above parameters pneumatic circuit development

Figure 4: PLC Ladder logic in Fluidsim

The PLC main part is ladder logic programming as per

sequence of operations in test specifications. Based on that
simulate the working of the circuit. If it is working as per
requirement then check timings and intervals in between
operations.
E. Development of ladder logic in PLC
Figure 2: Pneumatic circuit Development of PLC ladder logic for test rig to automate the
testing sequence
D. Simulation of pneumatic circuit in Fluidsim
The simulation of the pneumatic circuit to study the system
working is necessary because if do practical things without
proper simulation it leads to the more investment of money as
well as time. So before by simulating of entire circuit will save
time and investment.

Figure 3: Simulation of pneumatic circuit in Fluidsim

Fluidsim is comprehensive software for the creation,
simulation, instruction and study of electro-pneumatic, electro
hydraulic and digital circuits. You'll be able to create circuits Figure 5: PLC Ladder logic in Fluidsim

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 International Conference on Energy, Communication, Data Analytics and Soft Computing (ICECDS-2017)
F. Development of SCADA screens for operational sequence
The Flow of the Control Program Sequence as per the Test
specifications for the BRAKE ACTUATOR ATE is detailed
as follows:
Figure 7: SCADA screen for the operational sequence
The Application asks for Confirmation to drain the Brake
Actuator Unit. Once this is confirmed, the Unit is drained after
making sure the Unit is properly clamped, and then the
following Screen comes up, asking to make sure the Parking
Brake Lever is dis-engaged.
Subsequently, the Application queries the Operator as to
whether Clamp or Unclamp the Unit. This is the default screen
that comes up if the operator initially selected not to drain the
Unit.
If the operator wishes to continue further testing, the operator
has to select the Clamp option. However, if the Operator
wants to remove the Unit for either Rectification Procedures
or for replacing the existing Unit with a new Unit, he can
select to Unclamp.
Now, if the Operator decides to unclamp the Unit, the
Application ensures that the Unit is properly drained before
doing so. The operator can now remove/rectify/replace the
Unit before proceeding further with the Tests.
However, after unclamping, the Application waits for the
Operator to complete all the preliminary work and mount the
next Unit. The Application displays the following screen,
prompting the operator to Clamp a Unit, once placed in the
Test-rig.
Once, the Unit has been clamped in place, the Application
displays the subsequent screen asking for the Operator to
initiate the Test Sequence.
Once this operation has been initiated, the Application
displays the following Screen to the operator. This is the
default Screen that comes up, once the Operator selects to
Clamp the Unit and directly proceed with the Test Sequence.
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Here, the Operator is prompted to select either the Parking or
Service Brake Unit as the one designated for the subsequent
Test Procedure.
Once the type of Unit that is to be tested has been selected, the
Test Sequence commences. The following Test Screen
appears, as the Mains Screen, as the Application executes the
Test Procedure. If the Unit that is being tested is a Service
Brake Unit, then the following first four Steps as shown on the
Screen will be carried out in sequence.
In the First Step, the Service Brake is applied, after
positioning the Screw-rod at the appropriate point, and the
distance traversed by the Brake Actuator Spindle is measured.
The release or backstroke or A-Measure of the Spindle is then
measured when the Service Brake Pressure is released.
The difference in the above two strokes or displacements is
then calculated and verified to be within the Specified Limits
or Tolerance Band.
In the Second Step, the screw-rod is again positioned, and the
Service Brake is applied and the Spindle is allowed to butt the
end-plate of the screw-rod. A load cell mounted on this end-
plate assembly, and properly cushioned by disc springs,
measures the Force exerted by the Brake Actuator upon
Service Brake Application. This Force is then checked to be
within the Tolerance Band or within the Specified Limits.
Now, as in the previous step, the Service Brake is released,
and the backstroke or the A-Measure of the Unit under test is
measured. This parameter is again verified to be within the
Tolerance Band or Specified Limits for that parameter.
In the Third Step & Fourth Step, the Application tests the
Leak in the Service Brake Unit under test at an applied Service
Brake Pressure of 0.6bar and 6bar respectively. The Leakage
is observed for a minute, and the end of the minute, the Leak
is checked to ensure it is within the Specified Limits or
Tolerance Band as before.
In all of the above steps, the parameters being tested, if not
found to be within the Specified Limits, the Application
displays the following Screen.
The Operator is prompted here to either continue with the
subsequent test steps or to retry the failed step. The parameters
that have failed to meet the Tolerance criteria are typically
displayed in their corresponding Cells in the background
Main-screen.
If the Unit that is being tested is a Parking Brake Unit, then
the following eight Steps as shown on the Screen will be
carried out in sequence.
The First Four Steps are the same as for a Service Brake Unit.
However, the next four steps, which are unique to a Parking
Brake Unit, are executed as follows.
 International Conference on Energy, Communication, Data Analytics and Soft Computing (ICECDS-2017)

Table 1: Manual testing vs. Automated testing The Operator is prompted here to either continue with the
Manual
subsequent test steps or to retry the failed step. The parameters
testing Automatic that have failed to meet the Tolerance criteria are typically
time in testing time in displayed in their corresponding Cells in the background
# Sequence for testing minute minute Main-screen.
1 Loading 5 1
2 Apply service brake 2 0.5 At the end of the Test Sequence – be it a Service Brake Unit
1 0.2
or Parking Brake Unit – the Application prompts the Operator
3 Measure of forward payout
to enter the Part/Body No. the Serial No. and also the Operator
4 Measure of Load 1 0.2
Name, before concluding the Test.
5 Release service brake 2 0.5
6 Apply service brake 2 0.5
A report is then generated, provided, the Unit under Test has
7 wait for one minute 2 0.5 passed All the Steps in the Test. If not, no reports are
8 Release service brake 2 0.5 generated and the Application then prompts the Operator to
9 preparation of test reports 5 0.5 reload the next Unit or initiate the next action to be carried
10 Unloading 5 1 out.
Total time in mins 27 5.4
III. RESULTS AND DISCUSSIONS
In the Fifth Step, the Parking Brake pressure is applied, and The simulation process was carried out using the Festo
the Force exerted by the Brake Actuator Spindle on the Load- Fluidsim software .The process of simulation is carried out as
cell is measured upon release of the applied pressure. Here, discussed in the previous chapter. This simulation of
the Spindle A-Measure is also checked after disengaging the pneumatic circuit with manual valves and manual testing
Parking Brake Lever, though only for reference. The Force is procedure time is noted down in the same time the automation
then checked if within the Tolerance Band or within the of testing with the PLC and SCADA system.
Specified Limits.
The testing time is carried out as per test specification in the
In the Sixth Step, the Application applies the Parking Brake manual mode as comparison with the automation mode.
pressure, releases it, and subsequently applies the Service
Brake pressure. Here the resultant Force or Effort generated As from the above table 1, we can conclude that manual
by the Brake Actuator on the Load-cell is measured and testing consumes more time than automatic testing.
checked again for the conformance to Tolerance Band or
Specified Limits.

In the Seventh & Eighth Steps, the Parking Brake pressure is

applied to the Brake Actuator and the Leakage is observed at
0.6 bar and 6 bar as before, for a minute. At the end of the
minute, the Leak is checked to ensure it is within the Specified
Limits or Tolerance Band as before.

In all of the above steps, the parameters being tested, if not

found to be within the Specified Limits, the Application
displays the following Screen.

Figure 9: Manual and automatic testing time representation

IV. CONCLUSION
¾ It involves the simulation of pneumatic circuit by using
Fluidsim which involves the analysis of the pneumatic
circuit which can reduce the analysis time for the
pneumatic circuit. By using this simulation can study the
test specification with same components as used in the
schematic as per standard.

Figure 8: SCADA screen for the failure of testing

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 International Conference on Energy, Communication, Data Analytics and Soft Computing (ICECDS-2017)

¾ The simulation results can also be used to study the
manual testing time and automation testing time with how
much force and forward payout of the actuator. Also it
helps in research in modularity of pneumatic circuit which
reduces the pneumatic circuit design with the same circuit
design as per standard.
¾ The PLC and SCADA design for test rig to automatic
testing which reduces the testing time and accuracy of
testing. Also it increases the overall productivity.
¾ Development of additional SCADA screen to change test
parameters and calibration of test rig automatically which
independent maintained of test rig which is more user
friendly. Also user name and password for each operator
which is increase the security of test reports. It is also
helps in the traceability of the test reports.
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Acknowledgment
We are grateful to the Faiveley transport rail technologies
India ltd. For giving us an opportunity to complete a PLC
based automation of testing machine with all support.

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