A Certification Course Report

on
PLC BASED ELEVATOR CONTROL SYSTEM

Submitted in partial fulfillment of requirement for the award of degree of

BACHELOR OF TECHNOLOGY
IN
ELECTRICAL AND ELECTRONIC ENGINEERING
BY

KALAKONDA BHARATH KUMAR (15K41A0225)

BONALA ABHILASH (15K41A0206)
GINDAM VAMSHI KRISHNA (16K45A0208)
ISLAVATH HARI KRISHNA (16K45A0212)
KADAVERGU ARUN KUMAR (16K45A0214)
 CERTIFICATE

This is to certify that this Certification course entitled “PLC BASED ELEVATOR
CONTROL SYSTEM”is a bonafide work carried out by Mr.KALAKONDA
BHARATH KUMAR (15K41A0225) BONALA ABHILASH (15K41A0206)
GINDAM VAMSHI KRISHNA (16K45A0208) ISLAVATH HARI KRISHNA
(16K45A0212) KADAVERGU ARUN KUMAR (16K45A0214), in partial fulfillment
of the requirements for the award of the degree of Bachelor of Technology in SR
ENGINEERING COLLEGE during the academic year 2018-2019 under our guidance
and supervision.

Ms. ANUSHALINI Dr. RAMDESHMUK

Sr.Assoc. Professor Professor & HOD,

SR Engineering College, SR Engineering College,

Ananthasagar, Warangal. Ananthasagar, Warangal.

 ACKNOWLEDGEMENT

I wish to take this opportunity to express my sincere gratitude and deep sense of
respect to our beloved Principal, Dr. V.MAHESH, for his continuous support and
guidance to complete this certification course in the institute.

I express my heartfelt thanks to our Head of the department, Dr. Ram Deshmukh,
for providing me with necessary infrastructure and thereby giving me freedom to
carry out the certification course.

I express my heartfelt thanks to coordinator Ms. ANUSHALINI for her

encouragement and support.

I express my gratitude to Advanced Training Institute for their guidance and

support.

Finally I would like to thank all the teaching and non-teaching staff of the
department for their suggestions and timely support.

CONTENTS
 ACKNOWLEDGEMENT iii
OBJECTIVE iv
LIST OF FIGURES viii
LIST OF TABLES ix
LIST OFACRONYMS x

Chapter No. Title

1 INTRODUCTION
1.1 What is a PLC?
1.2 Need for PLC
1.3 History of PLC
1.4 Advantages
1.5 PLC Architecture
1.6 Working of PLC
2 CERTIFICATION COURSE
2.1 Ladder Programming Algorithm
2.1.1 Ladder Logic
2.2 Implementation of PLC Based Elevator Control System
2.2.1 Power supply unit
2.2.2 Description of Hall Effect Sensor
3. OUTCOME OF THE COURSE
4. CASE STUDY OF CERTIFICATION
5. CONCLUSION

INTRODUCTION
For most people residing in urban cities, elevators have become an integral part of
their daily life. Simply stated, an elevator is a hoisting or lowering mechanism,
designed to carry passengers or freight, and is equipped with a car and platform
that typically moves in fixed guides and serves two or more landings. Hydraulic
and roped elevators are the two types of elevators in use today. The main design
considerations for choosing either electric traction drive or hydraulic for a
particular project are the number of floors, the height of the building, the number
of people to be transported, desired passenger waiting times and frequency of use.
This project is to design and construct an elevator using a programmable logic
controller. Hall Effect sensor is used to know the elevator position. Hydraulic and
roped elevators are the two types of elevators in use today. Elevators are prevalent
throughout many multi-level structures

What is a PLC?

A Programmable Logic Controller (PLC) is an industrial computer control system

that continuously monitors the state of input device and makes decision based upon
a custom program to control the state of output devices. Almost any production
line, machine function, or process can be greatly enhances using this type of
control system. However, the biggest benefit in using a PLC is the ability to
change and replicate the operation or process while collecting and communication
vital information. Another advantage of PLC system is that it is modular. That is,
you can mix and match the type of Input and Output device to best suit your
application

According to NEMA (National Electrical Manufacture Association)

”PLC is a digitally operated electronic system, designed specially for the use in
industrial environment, which use programmable memory for internal storage of
user oriented instruction for implementing specific function such as logic,
sequencing, timing, counting & arithmetic to control, though digital & analog input
&output for various type of machines & processes.” Both the PLC & its associated
peripherals are designed so that they can be easily integrated into an industrial
control system & easily used in all intended functions.

Need for PLC:

Hardwired panel were very time consuming to time and debug and change.
The following requirement for computer controller to replace hardware panel.
Solid state not mechanical East to modify input and output device
Easy programmed and maintained by plant electrician Be able to function in an
industrial environment
History of Programmable Logic Controller (PLCs):

1968: Design of PLCs developed for General Motors Corporation to eliminate

costly Scrapping or assembly line relays during model changeovers.
1969: First PLCs manufactured for automotive industry as electronic equivalent of
relays.
1971: First application of PLCs outside the automotive industry.
1973: Introduction of “smart” PLCs for arithmetic operations, printer control
move, Matrix operations, CRT interface etc.
1974: Introduction of analog PID (Proportional, integral, derivative) control, which
made possible the accessing of thermocouples, pressure sensor etc.
1975: First use of PLCs in hierarchical configuration as part of an integrated
Manufacturing system.
1977: Introduction of very small PLCs based on microprocessor technology.
1978: PLCs gain wide acceptance, sales approach $ 80 million.
1979: Integration of plant operation through a PLC communication system.
1980: Introduction of intelligent input and output module to provide high speed,
accurate control in positioning applicants.
1981: Data highways enable user to interconnect many PLCs up to 15000 feet from
Each other. More 16-bit PLCs become available. Color graphic CRTs are available
from several suppliers.
1982: Larger PLCs with up to 8192 I/O become available.
1983: “Third party” peripherals, including graphic CRTs, operator’s interface, I/O
networks, panel displays, and documentation packages, become available from
many so

Advantages:

Before getting into details about PLCs, lets us know 3 reasons why PLCs are being
widely used these days

 They are user friendly and easy to operate

 They eliminate the need for hard wired relay logic
 They are fast
 It is suitable for automation in industries.
 Its input and output modules can be extended depending upon the
requirements
PLC Architecture:

PLC Internal Architecture

A basic PLC system consists of the following sections:

 Input/ Output Section: The input section or input module consists of

devices like sensors, switches and many other real world input sources. The
input from the sources is connected to the PLC through the input connector rails.
The output section or output module can be a motor or a solenoid or a lamp or a
heater, whose functioning is controlled by varying the input signals.

 CPU or Central Processing Unit: It is the brain of the PLC. It can be a

hexagonal or an octal microprocessor. It carries out all the processing related to
the input signals in order to control the output signals based on the control
program.

 Programming Device: It is the platform where the program or the control

logic is written. It can be a handheld device or a laptop or a computer itself.

 Power Supply: It generally works on a power supply of about 24 V, used to

power input and output devices.

 Memory: The memory is divided into two parts- The data memory and the
program memory. The program information or the control logic is stored in the
user memory or the program memory from where the CPU fetches the program
instructions. The input and output signals and the timer and counter signals are
stored in the input and output external image memory respectively.
Working of a PLC:

 The input sources convert the real time analog electric signals to suitable
digital electric signals and these signals are applied to the PLC through the
connector rails.
 These input signals are stored in the PLC external image memory in
locations known as bits. This is done by the CPU
 The control logic or the program instructions are written onto the
programming device through symbols or through mnemonics and stored in the
user memory.
 The CPU fetches these instructions from the user memory and executes the
input signals by manipulating, computing, processing them to control the output
devices.
 The execution results are then stored in the external image memory which
controls the output drives.
 The CPU also keeps a check on the output signals and keeps updating the
contents of the input image memory according to the changes in the output
memory.
 The CPU also performs internal programming functioning like setting and
resetting of the timer, checking the user memory
 CERTIFICATION COURSE
The small-scale elevator model with PLC is adopted for the controller design
which uses the Ladder Language based on the GE FANUC Versamax PLC. The
ladder logic has implemented by using Versa Pro. 2.02. In this control design
technique, the Light Dependent Resistor (LDR) is used to sense the elevator
floor.GE FANUC Versamax PLC is having a configurable memory of 64kbyte.
The author provided to improve the quality in elevator systems, develop and drives
the used setting and increase the reliability of elevator. The author also mentioned
to achieve high speed nine-phase Permanent Magnet Synchronous Motor
Control System. The author mentioned that making of wireless module to realize
the transmission of user information, PLC control system are adopted, the serial
communication mode between the PLC and the wireless module was adopted.
SI4432 Transceiver, Single-Chip computer and PLC are used to modify the control
system of construction elevator. The control system of the construction elevator
was made up of PLC, wireless calling device and wireless host transceiver.
Elevator control system can determine the next travel direction based on the call
information and the current operation automatically, realizes unattended operation.

The application of sate chart to the modeling, design and implementation of an

elevator system, whose system behavior involves aggregating complexity of state
descriptions, and imposition of underlying control policy. Based on the operational
flow of an elevator, they derive the associated state chart model
by looking into the inherent hierarchical structure of the elevator. This research
was supported in part by the grant NSC90-2213-E-011-020 and NSC90-2212-E-
014-023 by the National Science Council, Taiwan, R.O.C.
PROGRAMMABLE LOGIC CONTROLLER:
The first Programmable Logic Controller, PLC was developed by a group of
engineers at General Motors in 1968. It was developed when that company was
looking for an alternative to replace complex relay control system. The term
‘programmable logic controller’ is defined by EN 61131-1 as a digitally operating
electronic system which uses a programmable memory for the internal storage of
user-oriented instructions for implementing specific functions such as logic,
sequencing, timing, counting and arithmetic to control through digital or analogue
inputs and outputs, various machines or process.
Ladder Programming algorithm :
There are many types of programming languages in Programmable Logic
Controller, PLC. Languages are typically fixed to Ladder Logic (LD), Sequential
Function Block (SFC), Function Block Diagram (FBD) and
Structure Text (ST). The common program language of PLC is ladder diagram.
Ladder Logic
Ladder diagram is an automatic control diagram language that developed during
World War II. Ladder logic is the primary programming language of
programmable logic controllers. Since the PLC was developed to replace relay
logic control systems, it was only natural that the initial language closely resembles
the diagrams used to document the relay logic. By using this approach, the
engineers and technicians using the early PLCs did not need retraining to
understand the program. To introduce ladder logic programming simple switch
circuits are converted to relay logic and then to PLC ladder logic. Any control task
modifications are done by changing the program. This is why the use of the PLC
is preferred to the traditional hard wired circuits in industrial controls.
Implementation of PLC Based Elevator Control System
In order to design a control circuit, it is divided into several units or modules for its
particular task or control which first can be tested or implemented independently
and then combined together. The basis of PLC based elevator control can be
classified into three main groups. The first is the floor, the second is the PLC
controller and the last is the Elevator. The block diagram of PLC Based Elevator
Control System is described in Figure 4 To accomplish the PLC based control
system, the design uses six major components: PLC controller, DC motor driver,
push button, level sensor, display unit and Elevator. Level sensors are used to
know the elevator position and push buttons are used to be input by the user
request. The display unit will display the number of floor. The PLC compares the
user request and the push button to drive the elevator motor Up or Down. When
the user request is greater than the sensor value, the motor will go up and it is less
than the sensor value, it will go down. When the two values are equal, the motor
must stop.
This design can be divided into several units or modules. They are sensor unit,
processing unit and power unit. There are some devices and components used in
the in the design to implement each unit. These devices used in this system are as
follows;
Power Supply Unit
Hall Effect sensor
IVC1 1410MAT PLC controller
H-bridge DC motor
Push Button
Display Unit
Elevator
Power Supply Unit:
The DC power supply unit is vital component in modern electronic devices as they
need a wide range of DC voltages for their operations. The purpose of a power
supply is to provide the required amount of power specified voltage from primary
source.

Description of Hall Effect Sensor:

A Hall Effect sensor is a transducer that varies its output voltage in response to a
magnetic field. Hall Effect sensors are used for proximity, positioning, speed
detection and current sensing applications. In its simplest form, the sensor operates
as an analogue transducer, directly returning a voltage. A Hall Effect sensor can be
used to measure the current without interrupting the circuit. Frequently, it is
combined with circuitry that allows the device to act in a digital (on/off) mode and
may be called a switch. It is commonly used to time the speed of wheels and
shafts, such as for internal combustion engine ignition timing, tachometers and
anti-lock braking systems. It consists basically of a thin piece of rectangular p-
type semiconductor materials. A typical Hall Effect sensor has three wires or
terminals; one for ground, one for supply or reference voltage and one for output.
To produce an output signal, it must be supplied with a voltage from 5 to 12 V.
There are many different types of magnet movements, such as Head-on,
Sideways, Push-pull and Push-push detections.
 OUTCOMES OF THE COURSE

1. Ability to gain knowledge on Programmable Logic Controllers.

2. Will understand different types of devices to which PLC input and output
modules are connected.
3. To provide the knowledge about understand various types of PLC registers.
4. Able to create ladder diagrams from process control descriptions.
5. Ability to apply PLC timers and counters for the control of industrial processes.
6. Able to use different types PLC functions, Data Handling Function.
7. Able to develop a "coil and contact" control system to operate a elevator and
PLC operations.

The main aims of the elevator control system are:

1. Able to bring the lift car to the correct floor.
2. Able to minimize travel time.
3. Able to maximize passenger comfort by providing a smooth ride.
4. Able to accelerate, decelerate and travel within safe speed limits.
 CASE STUDY OF CERTIFICATION
For planning of our project work it is divided into two parts:

1. Making the control circuit for elevator

2. Making the hardware model of three floor elevator

Full description of planning of our project work:

1. Making the control circuit for elevator: for control the elevator system through
plc we can making the control circuit.

Following circuit are made:

1. BCD to seven segment display circuit:

Description:

The display uses seven (7) segments in order to represent the decimal numbers 0-9.
The numbers are formed when they light some of the parts of the seven segment
display.
There are displays which use light emitting diodes (LEDs) for the construction of
their segments. They are constructed in two types, common anode where all the
diode anodes of the segments are connected together and the ones of the common
cathode where all the cathode diodes of the segments are commonly connected.

This BCD to seven segment display indicates the current floor position of elevator
in our project.

2. IR object sensor circuit:

Fig. Sensor circuit

Description:

Here three sensors are required for different three floor model.ir object sensor
detect the object (elevator) current position.

One IR sensor is installed into elevator and three IR sensors are also installed
at three different floors. When the elevator is reach at any floor than that particular
floor sensor communicate with it and receiving the signal value which is
comparing the value.

For comparing signal value comparator IC LM358 is used. Which is comparing

this value with the preset value in IC. If the signal value is greater than the preset
value it is shows the floor number in display neither do not shows any result.

3. Relay control circuit:

Control circuit is controlling the elevator in upward and downward direction. It is
also control the door close and open of the elevator

It is a controlled by the electro-magnet relay.

When the two relays are energized lift is moving upward and other two relays are
energized lift is moving downward.

Here this figure shows that if the two relays are energized than gate is open and if
the other two relays are energized than door is close of the elevator.

3. Making the hardware model of three floor elevator:

 For the making of three floor elevator hardware model we are using the acrylic
material which is easy to construct and transparent material for elevator door we
are use the cd drive box to door open and closed.

Material and method used in project:

As material of our project we are using the different component follows:

Component:

1. Dc motor

2. Electromagnet relay

3. Opto Coupler (photo transistor)

4. IC 7447

5. Push button switch

6. Common resistor anode display

7. BC547 transistor

8. LM358 comparator IC
Description for all above components as following:

1. Dc motor:

The dc motor works on the principle of Fleming’s left hand rule. When current
carrying conductor is kept in the magnetic field a force is produced on the
conductor in a definite direction.24v DC motor is used.

2.Common Anode Display:

3. Optocoupler:

Optcoupler is combination of light source and light detector. It is also called as

Opto Isolater . It provide a complete electrical isolation between a low power
control circuit and high power output circuit to protect control circuit.

4.Photo Transistor Optocoupler:

In this infrared led act as light source and photo transistor act as a detector when
pulse input goes high led turn on light emitted by led is focus on collector base
junction of photo transistor collector current of photo transistor start flowing the
pulse input reduce to zero led off collector current zero

Merits:

1. Small size, light weight

2. Control circuit is protect due to electric isolation

3. Unidirectional signal transfer

4. Logic circuit is easy.

Demerit:

Slow speed

Applications:

1. AC to DC converter used for dc motor speed control

2. High power chopper
3. High power inverter

4. Electro Magnetic relay:

Electromagnet type of relay that can handle the high power required to directly
drive an electric motor is called a contactor. Solid-state relays control power
circuits with no moving parts, instead using a semiconductor device top form
switching.

5.IC 7447:

IC 7447 is a one type of BCD to seven segment decoder IC .

It accepts binary coded decimal as input and convert into drive seven
segment for displaying digits 0 to 9.

BCD is an encoding in
which each digit of number is
represented by its own binary sequence.

6.BC547 Transistor :
Fig. Shows a NPN transistor. It can be used as the active component for switches
and amplifiers.

To make use of a transistor as an audio preamplifier, a direct current is needed

such as a 24v power supply in a common emitter configuration. The negative side
of the power supply is ac coupled to the emitter via capacitor. There is also small
resistance connecting the power supply to the emitter.

7.LM358 comparator IC:

It is a one type of operational amplifier. It consist of two independent high gain

operational amplifier in one package. This IC can be operated on wide range of
power supply from 3v to 32v for single power supply.
 Positive pin is used for positive feedback and negative pin is use for
negative feedback. When voltage at pin2is more than voltage at pin3 it will raise
the output towards the positive maximum voltage and a slight increase at negative
pin compare to positive pin will lower the output towards the negative maximum.

Ladder diagram of Elevator :

 CONCLUSION
Lift, as the common tool, is widely used in the world now. In another word, it is
very important in our lives. So we choose lift as our thesis topic. After that, we
begin to search the details about the lift, and we know some components about the
lift, such as car, hoist way, counterweight frame, etc. And there are many kinds of
lifts for different uses, for example, passenger lift, hospital lift, freight lift and so
on.

From the research about the history of Chinese lift, we know that Chinese
companies have produced more than 610,000 lifts, and with the economic
development, Chinese market need more and more lifts, it is a big market demand.
With increasing number of the demand, it is very easy to improve the technology
of the lifts. Currently, PLC control system has become the mainstream of the lifts,
it owns high operational reliability, easy maintenance, strong anti-interference
design and debugging cycle is short.

Then we do some researches about PLC control system, to design the system, we
must select some hardware firstly, next, we could begin to design the software
about PLC control system. And we know something about the PLC programming
language and STEP 7 can be used to design the software.

In addition, we also want to know the future of the lift, which kinds of technology
can be used in the lift, and how convenient it is. And maybe we can get some new
things to save energy, which is the same as saving money.

In conclusion, we expect the future of the lift, and we want we can see
some technologies which have been mentioned above. And it must make
our lives more convenient.