PLC (PROGRAMMABLE LOGIC

CONTROLLER) BASED LIFT

AUTOMATION SYSTEM

MD. SK. ABDUL AWAL

Student No : 062206P

DEPARTMENT OF ELECTRICAL AND ELECTRONIC ENGINEERING

DHAKA UNIVERSITY OF ENGINEERING AND TECHNOLOGY,GAZIPUR
April, 2011
PLC (PROGRAMMABLE LOGIC CONTROLLER) BASED
LIFT AUTOMATION SYSTEM

A PROJECT REPORT

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

Of
M. Engineering

In
ELECTRICAL AND ELECTRONIC ENGINEERING

By

Md. Sk. Abdul Awal

Student No : 062206P
Session: 2006-2007
Reg. No: 04089

Under supervision of

Dr. M. Bashir Uddin

Professor & Head

DEPARTMENT OF ELECTRICAL AND ELECTRONIC ENGINEERING

DHAKA UNIVERSITY OF ENGINEERING AND
TECHNOLOGY,GAZIPUR
April, 2011
 DECLARATION

I hereby declare that this project or any part of the project has not been submitted
elsewhere for the award of any degree or diploma

Signature of the candidate

………………………….
Md. Sk. Abdul Awal
 CONTENTS
1. ACKNOWLEDGEMENT
2.ABSTRACT
3.CONTENTS
4.LIST OF FIGURES
5. LIST OF ABBREVIATION

Chapter 1: Introduction

1.1 Introduction…………………………………………… 01
1.2Objective……………………………….…………………03

1.3Organizationoftheproject…………..………………...……………...03

Chapter 2: PLC Architecture

2.1: Introduction
2.1.1BackgroundDevelopment………………………………….. 04
2.1.2BlockDiagram…………………………………………... 05
2.1.3 ChoosingthePLC….............................................................. 06
2.1.4Communication…………………………………………... 06
2.1.5 PLCSpecification………………………………………… 08
2.1.6 Advantage …………………………………………………10

2.1.7 Disadvantage……………………………………………... 11

2.2 : Operation
2.2.1 Operation of PLC ………………………………………………… 11
2.2.2 Functional description ………………………………………………. 12
2.2.3 Function of PLC as a controller …………………………………….. 13

2.3 : Hardware description

2.3.1 Input & output module……………………………………………. 14
2.3.2 Program loader………………………………………………………...15
2.3.3 power supply unit ……………………………………………………..15
2.3.4 Microprocessor……………………………….………………………...16
2.3.5 Memory unit ……………………………………………….…………..16
2.3.6 Input section …………………………………………………………..16
2.3.7 Output section………………………………………………………….17
 2.4 : Software & programming language
2.4.1 Programming concept………………………………………………….18
2.4.2 Ladder diagram ……………...……………………….………………..18
2.4.3 Programming device………………………………………...…………29
2.4.4 Instruction……………………………………………...………………20
2.5 : Troubleshooting & Maintenance
2.5.1 Troubleshooting……………………….…………………….…………21
2.5.2 Maintenance……….……………………………………….…………22
2.5.3 General procedure of repair………………………………….………...24

Chapter 3: Project Description

3.1: Introduction ….............................................................................25

3.2 : Working Procedure

3.2.1 Before starting of the project…………………………………………27
3.3.2 Starting of the project …….………………………...………’………..28
3.2.3 Start and Observation…….…………………………….…’…………28

3.3 : Function
3.3.1 How to work it ………………..….….. ……………………………29
3.3.2 Loading & unloading function ………………………………….......29
3.3.3 Carrying function ……………………………………….…………./30
3.3.4 Safety function ………………………………………..………… 30

3.4 : Major parts and its function

3.4.1 Lift mechanism ……………………………………………………. 31
3.4.2 Conveyor function …………………………………………..……. 32
3.4.3 Motor function………………………………………………….......32
3.4.4 Sensor function ………………………………………….……..…. 33

3.5: Related device

3.5.1 PLC …………………….……………………….….………….… 33
3.5.2 Relay ……………………………………….….………………….34
3.5.3 Switch …………………………………………….…………….…36
3.5.4 Sensor ……………………………………………………….….... 37
3.5.5SMPS................................................................................................39
 3.5.6 DC Motor …….…………………………………..…………….....40

3.6:PLC Connection…………………………………………………………43
3.7: Advantage…………………………………………………………….….44

Chapter 4: Software and Programming

4.1. Introduction………………………………….……………………….…45
.
4.2: Programming language……………………………….…………….45

4.3: Ladder Diagram………………………………………….….……….46

4.4: KGL WIN

4.4.1 Feature……………………………………..…….….……………48
4.4.2 System requirement……………………..….…..........................48
4.4.3 Installation………………………..………................................ 49
4.4.4 Communication cable……………..…………............................49
4.4.5 Symbols………………………………..…..……………………..49

4.5: Application
4.5.1 Creating a project………………………….............................. 56
4.5.2 Creating a program…………………….………........................56
4.5.3 Upload & download………………………….……..................56
4.5.4 Online edit…………………………….…….…………….........57
4.5.5 Variable/Comment……………………..…….…………………57
4.5.6 Monitoring ……………………………...……………………....57
4.5.7 Save the project………………………………..........................58
4.5.8 Menu……………………………………………......................58

4.6 : Instruction
4.6.1 Timer instruction…………….…………………………………60

4.6.2 Counter instruction………………….…………………………..62

4.7: Using ladder diagram & description

4.7.1 Ladder diagram……….……………………………..64

4.7.2 Description……….………………………………….66
Chapter 5: Performance Test
5.1 Introduction………………………………………………68
5.2 Performance………………………………………………68

Chapter 6: Discussion & Conclusion

6.1 Conclusion…………………………………………………..…70
6.2 Future enhancement………………………………………......71

References………………………..……………………..…72
 ACKNOWLEDGEMENT

PLC (Programmable Logic Controller) based Lift Automation System is a

intelligent and challenging task. To complete this project work various
persons/institute/company help me in various ways. I wish to record sincere thanks
to all of them.

First of all I wish to express my indebted thanks to DR. M. Bashir Uddin,

Professor and Head, Department of Electrical and Electronic Engineering, DUET,
Gazipur for his all time guidance, inspiration, valuable suggestion and supervise of
my project.

I wish to express my thanks to Professor Engr. Md. Abdul Mannan, Dean, Faculty
of Electrical and Electronic Engineering, DUET, Gazipur and Dr. Md. Anwarul
Abedin, Associate Professor,Department of Electrical and Electronic
Engineering,DUET ,Gazipur , as for their initial guidance, inspiration and valuable
suggestion for my project.

I would like to express my thanks and regards to Palash Kumar Banerjee,

Assistant professor, Department of Electrical and Electronic Engineering, DUET,
Gazipur, for his total support to materialize my project. I am indebted to him for
his constant guidance.

My Special thanks to Md Muslim Uddin, Md. Nurul Huda (Ripon), Md. Atiqur
Rahman Sub Asst. Engineer and Md Shahadat Hossain, Md Arif Hossain,
Technical Expart of WALTON Hi-Tech Industries Ltd. and finally my thanks to all
staffs of DUET central library and EEE departmental Library.

I am thankful to my family and friends who have provided support and

encouragement during my academic studies.

Finally I am grateful to Almighty Allah that I have completed the project

successfully.

iii
 ABSTRACT

Lift is usually used to carry man, machines, goods & others from one floor to
another floor in different industries, firms, homes, shopping mall &another places
where there is a high rise building or tower, at least more than one floor. There is a
movable case in the lift structure, which can moves with man or goods if it is
necessary. Four motors are used for the project three of them are 100w, 24vdc &
with gearbox who’s are used for the conveyors & another one which is 150w,
24vdc is used for carrying the main lift.

Three photo sensors are used to realized the status of the products or goods. Two
proximity are used for make, the up &down limit of the lift. Eight relays are used
for switching the four motors by using output command of the PLC. There is a
SMPS, which is 220v ac to24v dc for PLC input outputs and sensors power.

It is a fully automation project by using most latest ‘PLC’ instrument. Which is

widely used as a ‘Industrial Computer’ in different industries for automation of
industrial processes. PLC works by looking at its input and depending upon their
state, turning on/off its outputs. The user enters a program, usually via software,
that gives the desired results.

Here I used ‘LS’ branded ’ PLC’ Which is master K 120 S series & K7M DR 30U.
It has 18 inputs & 12 outputs. The input voltage range is 24vdc, 7mA& output is
220vac or 24V DC,2A/5A. It is embedded with its internal 24vdc, 0.7mA &
power LED in both input & output sides.

Its activated power is 220v ac & it supports RS-485,RS-232 serial ports for its
communication. It supports more programming languages like ladder diagram,
mnemonic code or instruction list.
Here I used ladder diagram by using ‘KGL WIN’ software for PLC programming.
‘KGL WIN’ is the programming software of all LS/LG brand PLCs.

iv
 LIST OF FIGURES

Fig. No. Figure Name Page No.

2.1.2 Functional block diagram of Master K-120 S Series.......... ... 05

2.2.2 Architecture of a PLC............................................................. 13

2.3.1 Functional block diagram…................................................... 15

2.4.3 A personal computer …......................................................... 19

2.5.2 Block diagram of PLC module………………………........ 23

3.2 Architectural view……………………………………..….... 27

3.4.2 Industrial belt conveyor system.…………………………... 32

3.5.1 PLC module…………………………………..……………. 33

3.5.2 Relay………………………………………….…………… 35

3.5.4(a) Photo electric sensor…………………………………….. 37

3.5.4(b) Inductive proximity sensor……………..………..……….. 38

3.5.4(c) Inductive proximity sensor working ……………………….. 39

3.5.5 Block diagram of a mains operated AC-DC SMPS with

Output voltage reg. ………..……………………….. 39

3.5.6 Structure of permanent magnet DC motor ……………….. 40

3.6 PLC connection……………………………………………43

4.4 KGL WIN………………………………………………….47

x
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Chapter 1
Introduction
1.1 Introduction
This is an automation project by using most latest, intelligent ‘PLC’ instrument
which is widely used as a digital computer in different industrial plant for
automation of industrial processes ,for its more advantages like cost effective,
higher reliability, easy maintenance, low power consumption etc.
Here I used ‘LS’ PLC which is master K 120 series & DR 30U model. For through
the power on it I used a power supply unit which is 220v ac to 24v dc. To sense the
lift status here are three photo sensors and for make the up-down limit of the lift
here are two proximity sensors. Four motors are used for this project. Three of
them for conveyor rotation and another one is for carrying the main lift. The
conveyors are tick roller type & made by PVC pipe. Eight relays are used for
switching the four motors which controlling command comes from PLC output &
a selector switch is used for select the forward and reverse mode.
The lift system worked both of forward & reverse modes. In forward mode it will
carry the product from down conveyor to upper conveyor. Inversely, in reverse
mode it will carry the product from upper conveyor to down conveyor. When we
select any mode (suppose forward mode), then down proximity get contact, the
down conveyor and the lift conveyor motor will run& the loading procedure will
start. After loading the product, it will carry the product towards the up conveyor.
When the up proximity sensed the lift, it will start the lift conveyor & upper
conveyor & thus the unloading procedure will start. After unloading, the lift will go
back to down conveyor, where there are waiting another product, thus a cycle will
be completed.
An instruction is a symbol or a group of letter, which initiate the PLC to perform a
specific function. A set or a group of predetermined instructions which activated
the PLC to desired sequential operations is known as program. The instructions
used for microprocessor based system is known as the language for the system.
Now a day’s different types of high level languages are available for programming
PLC, which provides commands and statements very closed to the actual functions.
 13
Programs for microprocessor based systems to be loaded in to the machine code,
this being a sequence of binary number to represent the program instructions.
However, assembly language is based on the use of mnemonics & a computer
program called an assembler is used to translate the mnemonics into machine code
program can be made easier by the use of so called high level language such as
C,BASIC,PASCAL,FORTRAN etc. These used of prepackaged functions,
represented by simple words or symbols. Descriptive the function concerned.
However, the use of these methods to write the program.
A PLC program requires some skill in programming and PLCs are intended to be
use by engineers without any great knowledge of programming.
As a consequence, different programming languages are developed. This is a
means of writing program instructions, which can be convert in to machine code by
some software or compiler used for a particular language.
Different PLCs have different programming facilities. Some PLC accepts one
language, but some PLCs accept more than one language. The widely used
programming languages for PLCs are the, a) Ladder diagram b) Instruction list c)
Functional block diagram. Here we used ladder diagram for programming. The
programming software of the all LG/LS brands PLC is KGL WIN. KGL WIN also
supports the instruction list.
The programmable logic controller is the replacement of conventional sequence
system. Such as electromechanical relays, timer, counter etc. A PLC is a digital
electronic system designed for use in automatic control system comprise of
programmable memory for the internal storage of instructions for implementing
specific functions. At the beginning PLC was designed to execute functions like
logic and sequential control of process timing and counting. But now PLC can
execute mathematical functions. The PLC handles digital signals normally. But the
modern PLC can handle all types of standard analog signals.
Basically a PLC operates by examining the input signals connected from the signal
process and carried out logic instruction on these input signals, Then it produces
output signal to drive process equipment or machinery, standard interfaces are used
in PLC, allow them to directly connect to the process transducer or actuators
without intermediate circuitry or relay.

1.2 Objective

a) The main objective of this project is to design and construction a PLC

(Programmable Logic Controller) based lift automation system to loading,
carrying and unloading the refrigerator in industry / firms.
b) To achieve knowledge about PLC hardware, software, input output
connection, trouble shooting and maintenance.
c) Know the knowledge about optical and magnetic sensors connections and
working procedures of this sensors.
 14
d) Working procedures of motors in forward and reverse direction by using
PLC.

1.3 Organization of the project

This project report consists of six chapters. Chapter 1 gives an introduction
of Programmable Logic Controller (PLC) in modern industries in lieu of relay
based system. Chapter 2 discuss about background and development of PLC, Block
diagram PLC specification, hardware description, software and programming
language and lastly trouble shooting and maintenance of PLC. Chapter 3 contains
the main description of the project such as working procedure function of the
project, major parts and it’s function, description of the related device and PLC
connection. Chapter 4 deals with the programming. Chapter 5 shows the
performance test and finally the discussion, conclusion and future enhancement are
described in chapter 6.
 15

Chapter 2
PLC Architecture
2.1 Introduction
2.1.1 Background & Development
In the early 1960s industrial control systems were constructed from traditional
electromechanical devices such as relays, drum switches and paper tape readers. In
1968 a team of control engineers (From General Motor of USA) wrote a
specification for what they called a PLC. What they specified was a solid state
replacement for relay logic. Instead of wires they would be bits inside of a memory
(Magnetic core memory) circuit that would dictate the logic. The machine would
use state outputs and in puts instead of control relays to control the motor starters
and sense push buttons and limit switches. The first commercially PLC was
introduced in 1969. During 1970 switch microprocessor based PLC was introduced
with intelligent I/O devices (both remote & local) and mnemonics .In 1985 the low
cost PLC were introduced by the Japanese. Networking of all levels of PLC,
computer and machines was developed in this year.PLC is developing at virtually
the same pace as microcomputers, with particular emphasis on small controllers,
positioning, numeric control and communications networks.

2.1.2 Block diagram

A programmable logic controller (PLC) is a special form of microprocessor based
controller that uses a programmable memory to store instructions and to implement
functions such as calculation, comparing and the processing of analog signals in
order to control machines and process. The programmable logic controller is the
replacement of conventional sequence system such as electromechanical relays,
timers, counters etc.
A PLC is a digital electronic system designed for use in automatic control system.
The system comprises of programmable memory for the internal storage of
instructions for implementing specific functions. The PLC can execute functions
 16
like logic and sequential control of process timing, counting, and mathematical
functions. The PLC handles digital signals. But the modern PLC,s can handle all
types of analog signals.
Basically a PLC operates by examining the input signals connected from the
process and carried out logic instruction on these input signals, then it generates
output signal to drive process equipment or machinery. Standard interfaces are
used in PLC, allow them to directly connect to the process transducer or actuators
without intermediate circuitry or relay.
Most PLC’s operate internally at between 5 and 15 v dc. But input and output
process signals possess higher voltages, typically 24 to 220 volts. The I/O units
from the interface between the microelectronics of the PLC and the real world
outside. It is standard practice for all I/O channels to be electrically isolated from
the controlled process, using optic-isolator circuit on the I/O modules.

Figure 2.1.2: Functional Block Diagram of MASTER K-120Sseries

2.1.3 Choosing the PLC
There is a massive range of PLC system available today. Some PLCs can handle
logic control & sequencing functions only. Some can handle more function like
data handling, communications, PID function etc. A PLC may be a single unit or
modular in construction. In modular PLC there may be a choice of CPU card
offering, different levels of performance interns of speed & functionality. There
should be the facility to increase input-output cards in future for fulfilling the
increasing demands. Hence a user should choice a PLC system according to his
/her requirement. The user must consider the manufacturers assistance. Relevant
hand books and manuals availability. Compatibility with other PLC system,
programming methods etc.

2.1.4 Communication
The most popular method of PLC is Rs-232 communication to external device
communication. Let’s tackle it piece by piece to see how simple it can be when we
understand it.Rs-232 is an asynchronous (a marching band must be in sync with
each other so that when one steps, are asynchronous in that they follow the band
leader to keep their timing ) communications method . We use a binary system
 17
(1’s and 0’s) to transmit our data in the ASCII format (American Standard code for
Information Interchange- pronounced ASS-KEY) this code translates human
readable code (letters/ numbers) into “computer readable” code (1’s and 0’s). Our
PLCs serial port is used for transmission / reception of the data. It works by
sending / receiving a voltage. Positive voltages called a MARK and a negative
voltage is called a SPACE. Typically, the PLC works with +/- 15volts.The voltage
between +/- 3 volts is generally not used and is considered noise.
There are 2 types of RS -232 devices. The first is called a DTE device. This means
data Terminal Equipment and a common example is a computer. The other type is
called a DCE device. DCE means data communication Equipment and a common
example is a modem. Our PLC may be either a DTE or DCE device . We need to
check documentation .The PLC serial port works by tuning some pins on while
turning other off. These pins each are dedicated to a specific purpose. The serial
port comes in 2 flavors—a 25 – pin type and a 9-pin type. The pins and their
purposes are shown below. (This chart assumes your PLC is a DTE device)

9-PIN 25-PIN PURPOSE

1 1 Frame ground
2 3 Receive data(RD)
3 2 Transmit data (TD)
4 20 Data terminal ready (DTR)
5 7 Signal Ground
6 6 Data set ready (DSR)
7 4 Request to send (RTS)
8 5 Clear to send (CTS)
9 22 Ring indicator(RI)*Only for modem*

 Frame ground – and this pin should be internally connected to the chassis of
the device.
 Received data – this pin is where the data from the external device enters the
PLC serial port.
 Transmit data – this pin is where the data from the PLC serial port leaves the
PLC enroots to the external device.
 Data terminal ready- this pin is a master control for the external device,.
When this pin is 1 the external device will not transmit or receive is data.
 Signal ground – science data is sent as + or – voltage, this pin is the ground
that is referenced.
 Data set ready-Usually external device have this pin as a permanent 0 and
the PLC basically uses it to determine that the external device is powered up
and ready.
 18
 Request to send- this is part of hardware .When the PLC wanted to send
data to the externals device it sets this pin to a 0. In other words it sets the
pin to 0 and basically says “I want to send you data. Is it ok? The external
device says it ok to send data by setting its clear to send pin to a 0 the PLC
then sends the data.
 Clear to send – this is the other half of hardware handshaking. As noted
above, the external device sets this pin to 0 when it is ready to receive data
from the PLC.
 Ring indicator-only used when the PLC is connected to a modem.

What happens when our PLC and external device are both DTE (and both DCE)
device. They can’t talk to each other that are what happens. The picture below
shows why same devices can’t communicate with each other.

DTE device DTE device

2 received 2 received
data data
3 transmit 3 transmit
Data Data

Notice that in the picture above, the receive data line (pin 2) of first device is
connected to the receive data line of the second device. And the transmit data line
(pin 3) of the first device is connected to the receive data line of the second device.
It’s like talking through a phone with the wires reversed. (I.e. our mouth piece is
connected directly to the other parties’ earpiece) Obviously, this won’t work well!
The solution is to use a null-modem connection as shown below. This is typically
done by using a reverse (null-modem) cable to connect the devices.
DTE device DTE device
2 received 2 received
data data
3 transmit 3 transmit
Data Data

To summarize everything, here’s a typical communications session. Both devices

are powered up. The PLC is DTE and the external device is DCThe external device
turns on DSR which tells the PLC that’s it’s powered up and “there”. The PLC
turns on RTS which is like asking the external device “are we ready to receive
some data? The external device responds by turning on its CTS which says it’s ok
for the PLC to send data. The PLC sends the data on its TD terminal and the
external device receives it on its RD terminal. Some data is send and receive. After
a while the external device can’t process the data quiche enough so, it turns off its
CTS terminal and the PLC pauses sending data. The external device.
 19
2.1.5 PLC Specification
General Specification:
1) Incoming power: it may be 24V, 110Vor 220V; DC or AC.
2) Input circuit voltage: 24v, 50V, 110V or 220V, AC or DC.
3) Output circuit voltage: Any of above or others.
4) Maximum power requirement: it depends on the size or capacity and
different types of constructions.
5) Hold up time: the processor a sustain operation for a few time may be 25 to
250 milliseconds.
6) I/0 capacity: Number of input and output points may be 20 to 1000 or more.
It depends on the construction of PLC.
7) Memory type: Normally it is CMOS RAM. It may be capacitor backup,
battery backup or EEPROM.
8) User memory capacity: It may be 800 to 3200 words or more.
9) Typical scan time: It may be a few microseconds to a few milliseconds per
1000 word program depending on the spaced of the microprocessor.
10) Internal relay type instruction: Its quantity may be a few tens to a few
thousand. It may be non-retentive or combination of retentive and non-
retentive.
11) Time base: Minimum time counted by timer is normally 0.1 sec. But there
may be the facility to count less than this time.
12) Timer range: Normally it is 0 to 999.9 sec. But there may be additional
facility to count 0 to 9999 sec and/ or 0 to 99.99 sec etc.
13) Sequencer capacity: It may be 8 bits * 100 steps or 16 bits * 100 steps or
more. Some PLCs may have no sequencer.
14) Vibration educability: It may be 500 to 1000 micro meter or more peak to
peak displacement. 25 to 50 m/sec acceleration or more. Frequency may be 1
to 10 Hz/axis or more.
15) Ambient temperature: 0 to 60 0 c or other values
16) Humidity insurability: 10 to 95%
17) Input / output modules: The main unit may have one more input/output
module.
Input specification:
1) ON state voltage range and frequency: Voltage may be 18 to 30 or 85 to 132
or 180 to 250. In general it is equal to rated voltage +/- 20%. The PLC cannot
work with the voltage out of this range. Frequency range may be 47 to 63 Hz
for ac.
2) Maximum OFF sate voltage: It is the voltage bellow which the PLC
considers its input states as OFF or ‘0’ level. It may be 5v, 30v, or 50v or other
value depending on its rated input voltage.
3) Maximum OFF state leakage current: It may be few micro amperes to 1 mA.
Low or no leakage current is desirable.
4) Nominal input current: It depends on input voltage. It may be a few mA.
 20
5) Input filter: There should be filter circuit in the input of a PLC to ground
against high voltage transients from external input device. This filter time ON
delay and OFF delay may be a few milliseconds.
6) Electrical – Optical Isolation: The input circuit voltage should be isolated
from control logical voltage by opto-coupler. This isolation capacity may be
1kv to 2kv

Output specification:
1) Output voltage range: 80 to 250v, DC/AC or others.
2) Continuous output current per circuit: It may be 1a to 5a or more. It depends
on construction and temperature.
3) Surge current: It is the maximum amount of current for a very little time at a
certain temperature with certain repeat frequency that the output can withstand.
Example: 10 A for 20 milliseconds at 30 0 C with repeat I per sec.
4) Maximum load current: The amount of current above which the PLC
considers its output as on state. It may be a few mille amperes.
5) Maximum off state leakage current: It may be few micro amperes to a few
mA.
6) OFF to ON response time: A few hundred microseconds.
7) Electrical-optical isolation: It may be 1kv between output voltage and control
logical voltage.
8) Maximum speed of counter: Maximum frequency of pulse that a counter can
count. It may be 20 Hz or more.
Some PLCs may have separate expansion units with processor unit. In this case the
specification of expansion unit may be different than that of processor unit. Some
PLCs may “hard contact relay outputs” with its separate output modules. This relay
output specification may be different the PLCs. A PLC should have its
programmer, microcomputer interface cards and program compiler & testing
software.
2.1.6 Advantage
 Easy to program
 Does not suffer from fatigue problem
 Cost effective
 Can be checked without field devices
 Can perform complex logic operation
 Faster system response
 Easy maintenance
 On-line On /Off facility of input and output
 Modular plug-in construction available
 Compact in construction
 Monitoring facility available
 Self diagnostics for troubleshooting
 Higher reliability
 21
 Can interface with computer
 Low power consumption

2.1.7 Disadvantage
 Handling large amount of data
 Displaying data
 Handling databases
 Complex data handling

2.2 Operation

2.2.1: Operation of PLC

A PLC work by continually scanning a program. We can think of this scan cycle as
consisting of three important steps. There are typically more than 3 but we can
focus on the important parts and not worry about the other. Typically the other are
checking the system and updating the current internal counter and timer values.

CHECK INPUT

CHECK INPUT

CHECK INPUT

Step 1: Check Input Status

First the PLC takes a look at each input to determine if it is on or off. In other
words, is the sensor connected to the first input on? How about the second input?
How about the third ... It records this data into its memory to be used during the
next step.
Step 2: Execute Program
Next the PLC executes your program one instruction at a time. May be your
program said that if the first input was on then it should turn on the first output.
Since it already knows which input are on/ off from the previous step it will be able
to decide whether the first output should be turned on based on the state of the first
input. It will store the execution results for use later during the next step.

Step 3: Update Output Status

Finally the PLC updates the status of the output. It updates the output based on
which input were on during the first step and the result of executing your program
during the second step. Based on the exmple in step 2 it would now turned on the
first output because the firs input was on and your program your said to turn on the
first output when this condition is turn . After the third step the PLC goes back to
 22
step one and reports the steps continuously. One scan time is defined as the time. It
takes to execute three steps listed above.

2.2.2: Functional Description

IN AN AUTOMATED SYSTEM, THE PLC IS COMMONLY REGARDED AS

THE HEART OF THE CONTROL SYSTEM. WITH A CONTROL
APPLICATION PROGRAM (STORED WITH THE PLC MEMORY) IN
EXECUTION, THE PLC CONSTANTLY MONITORS THE STATE OF THE
SYSTEM THROUGH THE FIELD INPUT DEVICES FEEDBACK SIGNAL. IT
WILL THEN BE BASED ON THE PROGRAM LOGIC TO DETERMINE THE
COURSE OF ACTION TO BE OUT AT THE FIELD OUTPUT DEVICES. THE
PLC MAY BE USED TO CONTROL SIMPLE AND REPETITIVE TASKS, OR
A FEW OF THEM MAY BE INTERCONNECTED TOGETHER WITH OTHER
HOST CONTROLLERS OR HOST COMPUTERS THROUGH A SORT OF
COMMUNICATION NETWORK, IN ORDER TO INTEGRATE THE
CONTROL OF A COMPLEX PROCESS.

A Programmable Logic Controller (PLC) is currently defined by National

Electrical Manufacturers Association (NEMA) as a digital electronic device that
uses as a programmable memory to store instruction to implement specific
functions such as logic, sequence, timing, counting and arithmetic to control
machines and process. It is the replacement of conventional sequence system such
as electromechanical relays, timers, counters etc. The PLC mainly handles digital
signals but in some special cases analog signal can be used. Normally, it receives
on or off (logical 1or 0) type input signal through its many input ports. Then its
processes the input signals in accordance with the instructions, which have been
stored into its memory previously. Then it produces on or off type output signals
according the instructions. It uses as a programmable memory for the internal
storage of instructions. The sketch of a PLC of 10 inputs and 10 outputs are shown
in the following figure. Here L, B and R (lamp, buzzer and relay) etc. are some
devices operated by PLC. Some different types of switches are shown that gives
the input signals to PLC.
 23

Figure 2.2.2: Architecture of a PLC

A PLC receives input signals from one or some processes and carries out logic
instructions ( Which have been programmed into its memory) on these input
signals; then it produces output signals to drive some process equipment. Standard
interfaces builds in the PLC allow them to be directly connected to the process
actuators or transducers without need for intermediate circuitry or relay. Then these
actuator or transducers can drive other actuators, machines or equipment.

2.2.3 Function of PLC as a controller

The programmable logic controller is the replacement of conventional sequence
system such as electromechanical relay, timer, counter etc. A PLC is a digital
electronic system designed for use in automotive control system. The system
comprises of programmable memory for the internal storage of instruction for
implementing specific functions. At the beginning PLC was designed to execute
functions like logical and sequential control of process, timing and counting. But
the modem PLC can handle all types of standard analog signals. Basically PLC
operators by examining the input signals connected from the process and carried
out logical instruction on these input signals, then it produces output signal to
device process equipment or machinery. Standard interfaces are used in PLC, allow
them to directly connect to the process transducer or actuators without intermediate
circuitry or really.
Most PLC operates internally at between 3.3 and 15v dc. But input and output
process signals process higher voltages, typically 24v to 220 volts. The I/0 (Input /
output) units from the interface between the microelectronics of the PLC and the
real world outside. It is standard practice for all I/0 channels to be electrically
isolated from the controlled process, using opto -isolator circuit on the I/0 modules.
 24
2.3 Hardware description
2.3.1 Input and output module
The input module converts the high level signals that come from the devices to
logic level signals that the PLC`s processors can read directly .The logic solvers
reads this inputs and decides what the output states be based on the users program
logic. The output module converts the logic level signals from the logic solver into
high level signals that are needed by the various field devices. To provide the
signals conversion, PLC is available with a choice of input /output units to suit
different requirements. The output and input may be as follows:
Inputs: Number of inputs = 8, 10,20,24,48,100,200 or any other quantity
Input Voltage = 5v, 24v, 110v or 240 V; DC or AC etc.
Or varying Voltage (1-5 V dc) or amperes
(4 - 20 mA dc) or combination of these.
Outputs: Number of Outputs = 8, 10,20,24,48,100,200 or any other quantity
Output contacts = 24v, 100mA; 110V, 1A/2A;
240V, 1A/2A/ 5A or other combinations.

Figure 2.3.1: Functional block diagram

2.3.2 Program loader/programmer

The Program loader/programmer is used to enter users program into the memory
(RAM) or change it and to monitor the execution of the program. In PLC the
program memory or user memory is a battery backup RAM normally or EEROM
where the instructions are stored. Now a days the personal computer (PC) is used
as Program loader/programmer.
 25

2.3.3 Power supply unit

The power supply unit may be integral or separately mounted. The basic function

of the power supply unit is to convert the field power into a form more suitable for

the electronic devices that comprise the PLC (3.3V, 5V or 12V). It always provides

the isolation necessary to protect the solid-state components. It provides power to

the I/O logic module, the CPU, the memory unit, and some peripheral devices.

2.3.4 Microprocessor

It receives the input data from the input circuit and gets command or instructions
from the program memory. Then it performs arithmetic and/ or logic functions in
accordance with the programmed instructions and produce outputs. These outputs
are sent to the output circuit, a microprocessor a number of inputs and produce
number of outputs simultaneously.

2.3.5 Memory unit

A memory chips consists of a number of memory cells into which data bits may be
stored. These memory cells are grouped together to form a memory location ( i.e.
one- bit , two -bit, four bit, eight-bit etc) . Data store in these locations are known
as words, A word is a group of binary bits forming the basic unit of information of
a system. Now days this basic unit of memory is formed with 6 bits group or 32
bit group. A four - bit word or number is referred to nibble and an eight-bit word is
referred to as a byte. Each location is given a unique code known as address for the
purpose of identification. There are different types of memory units such as
follows:
ROM: Read only memory. We can read the data from this memory, but we cannot
writ (store) any data or instructions into this memory.
RAM: Random Access Memory. We can read any data or instruction from this
memory and we can write any or instruction into this memory. If power fails then
all data will be erased automatically.
PROM: Programmable read only memory. By using a special program, we can
write any data or instruction into this memory for only one time.
 26
EPROM: Erasable PROM. By using Ultraviolet ray, w can erase the contents of
EPROM.
EEPROM: Electrically Erasable PROM. We can erase the contents of an
EEPROM by a special electrical signal.

2.3.6 Input section

Digital input: Switch, sensor and other device that give to the PLC input
Commands about their states. PLC input must convert variety off logical levels to
the 5vdc logical levels used on the data bus. This can be done with circuits similar
to those shown below. Basically the circuits condition the input to drive an opto
coupler. This electrically isolates the internal electrical circuitry from the internal
circuitry. Other circuit components are used to guard against excess or reversed
voltage polarity.
Input module: Forms the interface by which input field devices are connected to
the controller. The terms " field" and ‘ real world ‘ are used to distinguish actual
external devices that exist and must be physically wired into the system .
DC Input: There are either PNP (Sourcing) or NPN (Sinking) transistor type
devices in DC input module. PLC has no mix NPN and PNP devices in the same
module. It can be used either PNP or NPN. He difference between the two types is
weather the load (in our case, the PLC is the load) is switch to ground or positive
voltage .An NPN type sensor has the load switched to ground whereas a PNP
device has the load has the load switched to positive voltage .Many Engineers says
that PNP is better (i.e. safer) because the load is switched to ground, but whatever
works for you is best. Just remember to plan for the worst.
The only thing accessible to the user are the terminals labeled common, input
0000, input 0001,inputxxxx…..the common terminals either gets connected to v+
or ground . Where it’s connected depends upon the types of sensor used. When
using a PNP sensor this terminal is connected to 0v (ground).
Analog Input: An analog input is a continuous, variable signal. Typical analog
inputs may vary from 0 to 20 milliamps, 4 to 20 milliamps or 0 to 10 volts. In the
example a level transmitter monitors the level of liquid in a tank.
Depending on the level transmitter, the signal to the PLC can either increase or
decrease as the level increases as the level I increases or decreases. There are also
thermocouples, RTD (PT 100, P 300) analog input available.
2.3.7: Output section
Output device: A discrete output is an output that is either in an ON or OFF
condition. Solenoids, contactor coils, and lamps are example of actuator device
connected to discrete outputs may also be referred to as digital outputs. In the
following example a lamp can be turned on or off by the PLC output it is connected
to the output device.
Output module: Forms the interface by which output field device are connected to
the controller. PLC employs an optical isolator which uses light to electrically
isolate the internal components from the input and output terminals.
 27
Analogue Output: An analogue output is a continuous, Variable signal. The output
may be as simple as a 0-10 vice level that drives an analog meter. Examples of
analog meter output are speed, weight, and temperature. The output signal may also
be used on more complex applications such as current - to pneumatic transducer
that controls an air -operated flow- control valve.
2.4 Software and Programming Language
2.4.1 Programming Concept
An instruction is a symbol or a group of letter, which initiates the PLC to perform a
specific function. A set or a group of predetermined instructions, which activates
the PLC to execute desired sequential operation is known as a program.
The instruction use for microprocessor system is known as the language for the
system. Now a day’s different types of high level languages are available for
programming PLC, which provides commands and statements very close to the
actual functions. Programs for impresser based system to be loaded into the
machine code, this beings a sequence of binary numbers to represent the program
instruction. However, assembly language is based on the use mnemonics and the
computer program called an assembler is used to translate the mnemonics into
machine code. Program can be made even easier by the use of so called high level
languages such as C , BASIC, PCAL , FORTRAN< COBOL etc. These used of
prepackaged functions, represented by simple words as symbols descriptive of the
function concerned. However , the use of these methods to write the PLC
programs requires some skill in programming and PLCs are intended to be use by
engineers without any great knowledge of programming as a consequence ,
different programming languages are developed . He is a men's of writing
program instruction , which can convert into machine code by some software or
compiler used for a particular language .Deferent PLCs have different
programming facilities some PLCs accept only more than one language , the
widely used programming language for PLCs are the ladder program , instruction
code, logical, circuit and sequential function chart ( SFC).

2.4.2 Ladder diagram

Very commonly used language of programming PLCs is based on the use of ladder
diagram. In this language different types of symbols, which is similar to hard
warred relay ladder circuit are used this program. The ladder diagram consists of
two vertical lines representing the power rails. Circuits are connected as horizontal
line, i.e. the rungs of the ladder, between two verticals.

Programming a ladder diagram, the curving conventions are followed:

1. The vertical line of the diagram represents the power rails between which
circuits are connected.
2. Each rung of the ladder defines one operation in the control process.
3. A ladder diagram is read from left to right and from top to bottom.
 28
4. Electrical must start with an input or output and must end with at least one
output.
6. Electrical devices are shown in their normal condition.
7. Particular device can appear in more than one rung of a ladder.

2.4.3 Programming Device

Figure2.4.3: A personal computer

A personal computer (pc) is the commonly used programming device. The
software allows users to create, edit, document, store and troubleshoot programs
the personal computer communicates, with the PLC. Processor via a serial or
parallel data communications link. Hand -held programming device are sometimes
used to program small PLCs. They are compact , inexpensive, and easy to use , but
are not able to display, s much logical on screen computer monitor.
 29
2.4.4: Instruction

Relay type Instruction: The symbols of relay type instruction for the ladder
program are as follows:

Symbols Commands / instructions name

Examine `on` No contact

Examine `of` No contact

Energize output / coil energize

Latch or set ( Latch used with Unlatch )

L
Unlatch or rest ( and set used with reset)
U

RS
Reset / de-energize output / coil de- energize
T

Generate pulse/ coil energize for signal scan

PL
S

generate pulse at rising input

generate pulse at dropping input

2.5 Trouble Shooting and Maintenance of PLC

2.5.1: Trouble Shooting
There are two general principles to guide our first approach to troubleshooting a
problem. The first principle is to observe the symptoms of the problem (on-line or
off-line monitoring). The second is to ask questions about the problem. By
applying both principles to the system the general functional area of the problem
can be identified once the problem read is identified general trouble shooting
techniques may be used to isolate the problem.
There are four general techniques to troubleshooting:
 30
1) System Function or System pattern technique: The problem is isolated to
specific equipment or functional area in the system by comparing what the system
is supposed to do what it is actually doing.
2) Signal or power flow tracing: The trouble is narrowed down to a particular
device, such as processor unit or expansion unit.
3) Voltage and resistance measurement: This can identify the exact cause of the
trouble, such as a dirty contact an open coil, or an input output problem, such as
short circuited output contact.
4) Substitution: This can be used to ensure that among several suspected
components the real problem is found by process of elimination.
The best way to start any troubleshooting job is to skim through the instruction
manual. The manufactures manual will tell us what the equipment does and how it
does. The manual will usually include lists of typical faults and probable causes
this type of information can be very useful and time saving. The normal situation
frequently requires the troubleshooter to work without manual relying only upon
his training, experience and a schematic diagram.

2.5.2 Maintenance
We can maintenance PLC in various ways, most of them are:
a) Preventive maintenance
b) On line maintenance
c) Off line maintenance
Before maintenance of PLC an engineer must have:
a) Training
b) Proper documentation
c) Spare parts
d) Practical working experience on PLC
Preventive Maintenance:
Preventive maintenance may do both on line and off line of the process plant.
Basically it is carried out during period of plant. Aim of preventive maintenance is:
a) To decrease unwanted shutdown time of process plant.
b) To smooth production & increase quality.
c) To gives log life of process instrument.

On line Maintenance:
On line maintenance information, we can get from on line monitoring sates of the
system.
Off line Maintenance:
Off line Maintenance is done in laboratory or shop. When troubleshoot is carried
out then we can take action as bellows:
 31
a) Depending on previous symptoms & information of operator action should be
taken.
b) Check all input and output deceive in the system - different switches, pilot
lamps, solenoids motor starters etc. Most of the problem is normally arise from
these devices.
c) Check to see if there is a “Burned" smell or unusual noise or vibration. d) Check
circuit diagrams and/ or equipment manuals to see if the symptoms mentioned have
suggested probable causes.
e) Analyze the circuit to locate the areas where indicators and symptoms suggest
trouble.
f) Make voltage checks in the device - many devices, such as contacts and control
relays, have replaceable parts, such as coils and contacts.
h) Lastly assembled PLC & test Program.

On Line Monitoring: One of the best ways to find fault or verify PLC is On Line
monitoring by PLC loader or PLC modules on rack. We know that there is CPU
module, Power supply module. Input & output modules on PLC rack. Every
module has status indication led lamps. Through these lamp we can monitor the
status of PLC self and process devices. Similarly by PLC loader (PC - based) we
can monitor the plant device status (ON/ OFF) and other factors. Below fig - 01&
02 shows PLC modules in PLC rack that has different kinds of status indict in
lamps.

Program

Input Input PLC Output Output

device Modules Processo Modules devices B
r

Power supply unit

Figure 2.5.2: Block diagram of PLC module

2.5.3 General procedure of repair

A general procedure when troubleshooting is out lined as follows:
a) Note all symptoms of trouble.
b) Ask questions of the operator.
 32
c) Look at all input and output device in the system - different switches, pilot
lamps, solenoids, motor starters, etc. Most of the problems are normally raised
from these devices.
d) Check to see if there is a “burned" smell or unusual noise or vibration,
e) Check circuit diagrams and /or equipment manuals to see if the symptoms
mentioned have suggested probable causes.
f) Analyze the circuit to locate the areas where indicators nod symptoms suggest
trouble.
g) Make voltage checks in the direction of power flow - start at the main breaker
and trace the power through to the final device in the circuit.
h) Isolate the problem device- motor starter, fuse, etc.
i) Repair or replace the device many devices, such as contacts and control relays,
have replaceable parts as coils and contacts.
 33

Chapter 3
Project Description
3.1 Introduction
This is the lift automation project by using most latest intelligent ‘PLC’ instrument,
which is widely used as an industrial computer in different industrial plant for
automation of industrial processes.
Any machine or process can be operated safely by logic sequence system. This can
be done by conventional logic compounds. Now a day’s relay logic component is
replaced by PLC. For a process operation, it is necessary to have logic diagram
according to the demand of the process and the PLC needs to be programmed
accordingly. In conventional sequence electromagnetic or solid state relay, timers,
counters etc are used as switching element. On the other hand, in PLC
microprocessor is used as a switching element.
In industrial automations PLC is widely used for its amazing advantages like
higher reliability, cost effective, easy maintenance, low power consumption, long
lasting, easy to program, easy to maintain, communication capability and many
more.
Here I used, LS branded ‘PLC’ which is master K 120S series & K7M DR-30U
model. To activate it I am thronging a 220v ac power supply on it. And for it input
signal here I used a SMPS which is 220v ac to 24v dc. To sense the lift status here I
used 5 sensors. There of these are photo electric type & two of these are proximity
sensors. Photo sensor sensed by the block of beam & proximity sensed by any
metal & they are used for the project. Three of these are for run the conveyor &
another one is for carrying the lift. The power consumption of the motor is 24v dc
& 100w. The motor which is used for carrying the lift is 150w, 24v dc. All motors
are gearbox type, because it improved motor power & lock the anti rotation which
 34
is occurred by the weight of load. The lift conveyors & the other conveyors are
stick roller type which is made by PVC pipe & it can rotate with the motor rotation.
The eight relay are used for control the four motors with both of forward & reverse
rotation by the controlling command of PLC which comes from its output side. A
three way selector switch is used for the stop, forward and reverse mode select.
The lift worked both of forward & reverse modes with fully automatically when I
select the forward mode the lift carries the product from down conveyer to up
conveyor & delivered it into the up conveyor. At first it is waiting for the lift in
down conveyor position, when the lift come in down conveyer position, then the
down proximity P0004 will get contact & it will start the down P0004 & lift
conveyor motor P0043 with reverse rotation. So, the product will loaded into the
lift. When it loaded,the middle position of the lift. The lift photo sensor P0003
sensed it & when it sensed anything it will stop the lift conveyor & start the lift
carrying motor P0044 with forward rotation so that the lift will go up. When the lift
will go up from down conveyor, the down conveyor sensor P0002 will stopped the
down conveyor to prevent the fall down of next product.
When the lift will going for up, in the way when it sensed the upper proximity
P0005 , which is in the upper conveyor position, it will stop the lift carrying motor
(P0044) & permitted to run the lift conveyor motor (P0045) & upper conveyor
motor (P0047) with forward rotation, so that the product will get unloading. When
it cross the upper conveyor photo sensor (P0006), then it allows going to down of
the lift where the lift motor (P0046) will run with reverse rotation until the down
proximity sensed. And thus a cycle will be completed. Here are enough safety to
avoid friction with one product to another product the lift does not up when upper
conveyor is loaded by any product. Another one is when the lift will up the down
conveyor photo sensor (P0002) prevent fall down of the product from down
conveyor. Prevent power function during clockwise & anticlockwise rotation etc.
It saves time, money, worker & work smoothly with more reliability easy
repairable facility makes it more attraction.
 35
3.2 Working Procedure
Lift Motor, M3

Sensor-1 Sensor-3
(Magnetic) (Optical)

Level 2 Conveyor Motor, M4

Sensor-2
(Optical)
Lift

Sensor-2 Sensor-1
(Magnetic) (Optical)

Lift Belt Motor, M2

Level 1 Conveyor Motor, M1

Figure 3.2: Architectural View

3.2.1 Before starting of the project

If we want to start the lift we should take some necessary steps. At first we need to
attach the both parts of lift while the lift conveyor has the same level with the upper
& down conveyor position. When it sensed upper & down proximity. Then we
should be sure that all the sensors and the motor are ok & need to check their own
position are ok. If there are not ok then need to adjust the upper & down proximity
sensor by manually moving of carrying motor m3 & adjust the photo sensors
according to the size of the product. After Suring that all the structure & sensors is
ok then we need to know about the voltage standard & load calculation to the
project. Here I used a power supply which is 220 v ac to 24 v dc for the input
signal of PLC. The controlling devices which controlled by the PLC. There also
operated by 24v dc. So we can arrange 220v ac source which is available around
our self. We should just apply a 220v ac source by using a combination socket in
power supply unit. After done that, we will see that the green LED of power supply
& the power indication of PLC which is red will light up. Be sure that all the relays
are 24v dc & they are in their own position. All of the photo sensors ray
transmission path are clean & it green LED will light up, and then we can think that
the lift is ready for doing its operation.
 36
3.2.2 Starting of the project
We should be decided that what condition to we want to see. If we want to see the
lift in forward mode should select the selector in right sided which is marked by
marker for ‘auto mode’. In the forward mode, we can see that the PLC 40 no.
output LED will light up. In case of reverse mode we should select the selection
right sided from off position when the PLC 41 no. Output will light up. Thus we
can run this project safely.

3.2.3 Start & observation

By using selector switch we can select that starting mode of the project. In forward
mode we can see that the lift will carried the product from down conveyor to upper
conveyor. Initially it will wait for the product on the down conveyor. When, the
proximity P004 get contact. It will start the lift conveyor & the down conveyor.
Both of the conveyors are situated in same line & level. So that the product can
load on the lift easily. After loading it wills carrying the product by using carrying
motor until it sensed with upper proximity P0005. P0005 is situated in the same
level & line of upper conveyor. So that the product will unload easily by using
upper proximity P005. When the unloading product sensed the upper conveyor
photo sensor it will permit the lift for go back & carrying another product which is
in front of down conveyor photo sensor & writing for the lift. It we see that
anything is abnormal case then we should found the problem & solved it.

3.3 Function of the project

3.3.1 How to work it
This is an automation system work with fully automatic function both of forward &
reverse mode. There is a selector switch for select the mode after through the 220v
ac power in the power supply unit we need select the mode. In forward mode we
need selector switch turn into forward position, when the 40 no. output of the PLC
will light up. In initial condition the lift need to stay in down conveyor position,
when the down proximity get contact in this position the lift conveyor motor & the
down conveyor motor will run with anti clockwise rotation. So that the conveyor
will run antilock & the lift will waiting for loading the product. After loading the
product it will stop the lift conveyor & start the carrying motor for carry it up,
when the lift sensor detect anything. The lift will stop when it sensed the upper
proximity. On the way when lift will up, the down conveyors will stop when it
sensed.
After reached the upper position the lift conveyor & the upper conveyor will run
with clock wise rotation for unloading the product. When the upper conveyor
sensor sensed the project it will run the lift carrying motor with anti clock wise
direction. So that the lift will go back & load the next product. Thus the lift
completes its cycle. Inversely, in reverse mode it will carry the product from upper
conveyor to down conveyor.
 37
3.3.2 Loading and Unloading Function
Loading & unloading is an automatic procedure for any production line where the
production line is attached with lift where the production line is attached with
conveyors. When the lift is in down conveyor position the lift conveyor & the
down conveyor will run reverse direction. So the product which is in the
production line, will going to the lift through the attached conveyor & lift conveyor
until the lift sensor sensed it. When the lift censor sensed it, it means that the
leading procedure is finished. Then the lift sensor stops the lift conveyor. It is also
used for the setting of the place where the product will stay & stop. Normally it is
the middle position of the lift conveyor.
After carrying the product the lift will stop on the upper conveyor position by the
upper proximity (p005) . When the proximity get contact it means the lift is ready
for unloading the product. The product will unload by using the lift upper
conveyors. When the both conveyors will run with the forward direction. It will
unload. The both of conveyors will run, when the upper proximity get contact.
Normally the proximity is set in the position of upper conveyor. So that the product
will go ahead by using the upper conveyor & to prevent the full down of the
product from the lift conveyor.

3.3.3 Carrying Function

Carrying function means of carry the product from one floor to another floor or
down production line to upper production line. In forward mode the lift carrying
the product from down conveyor to upper conveyor. Inversely the lift carrying the
product from upper conveyor to down conveyor when the reversed mode will
selected.
When the lift sensor sensed anything, then the carrying procedure will start in
forward mode it will start form the down conveyor toward the upper conveyor by
the carrying motor (M3).Which is situated on top to the project. It is like an
overhead Crain. And when select the reverse mode it will work inversely of
forward mode. To smoothly up & down there are U shape clam in the below side of
support bar of the lift.

3.3.4 Safety function

In the lift system where are more movable pants. There safety is must there are
enough safety on it. When the lift will up from the down conveyor, then if the
down conveyor is running condition & there have any product in the conveyor, the
product will fall down the conveyor & damaged. There is a down conveyor photo
sensor while identify is (P002) on the down conveyor. When lift will up then it stop
the down conveyor when it sensed. Inversely the photo sensor (P006) which is in
up conveyor. Another safety is when the lift will go back from conveyor sensor, it
is not allowed the lift for up or that the product which is in lift, can’t friction with
the upper conveyor product. Inversely the down conveyor sensor (P0002) does not
allowed the lift to go back down when it sensed does not allowed when it sensed
anything or any product. The lift sensor (P003) is another safety which makes limit
for the product entrance. When it sensed, it will stop the lift conveyor. So that the
 38
product move more & can’t friction with lift case. Another one is when the lift will
carrying by the carrying motor the proximity sensor P005 & P004 make the up &
down limitation for the lift. When then sensor sensed, it will stop the carrying
motor. There are excellent safeties for one motor. One relay is for forward direction
& another one is for reverse direction. And one motor can’t run with both of two
directions by using same relay. That is preventing the short circuit. When it sensed
anything or any product. The lift sensor (P003) is another safety which makes limit
for the product entrance. When it sensed, it will stop the lift conveyor. So that the
product move more & can’t friction with lift case. Another one is when the lift will
carrying by the carrying motor the proximity sensor P005 & P004 make the up &
down limitation for the lift. When then sensor sensed, it will stop the carrying
motor. There are excellent safeties for one motor. One relay is for forward direction
& another one is for reverse direction. And one motor can’t run with both of two
directions by using same relay. That is preventing the short circuit.

3.4 Major parts & its function

The major parts at this project are:
 Lift mechanism
 Conveyors
 PLC
 Motor
 Sensor

3.4.1 Lift Mechanism

The main lift is a rectangular shape conveyor structure where are more than six
sticks type roller who’s are made by plastic pipe. The roller is decorated one by
one with a little bit of gap, according to the product size and they are coupled by
festoon rubber with one to another & finally the last roller is coupled by the motor
pulley. So when the motor will run the conveyor will run according to the motor
direction. To carry the lift up & down, there are a balance pipe which is in the top
position of the lift conveyor & attached with conveyor by another two pieces short
pipe bar. And finally the balance pipe is coupled with the overhead crane on lift
carrying motor. For smoothly up down there is a U shape clamp in the both support
bar.

3.4.2 Conveyor function

There are used two conveyors [1] in the project. One called down conveyor &
another is upper conveyor. Both conveyors are controlled by the motor. The
 39

Figure 3.4.2: Industrial belt conveyor system

Conveyor is like a road or path which is used for loading & unloading of procedure
of the product. In the conveyor there is a lot of roller whose are stick type & made
by plastic pipe. They are coupled one with another & decorate one by one with a
short gap according to the size of product. They are attached one with another by
the testator rubber & finally the last roller is coupled with motor pulley, so that
when it will run the conveyor will run one by one in series.

3.4.3 Motor Function

Motor is an electromechanical device which converts electrical power to
mechanical power. In the project we use four DC gear motor. The gearbox is a
mechanical device which improved motor power & necessary part in case of the
some applications like conveyor system because it can lock the load. When the
load will try to back by its own weight it also can operate the load with smoothly
handle.
Uses four motor are the down conveyor motor up conveyor motor, lift conveyor
motor & lift carrying motor. Both of them are dc 24v, 100w, only one motor which
is used for carrying the lift is 24v dc & 150 w. There is a pulley with the motor
shaft for proper coupling with the load.
3.4.4 Sensor Function
Sensor is a compact electronics device which worked with its sensed according to
it’s designed & give an output for control. Here I used the photo electric sensor,
which is both of PNP & NPN type. In the project I used NPN types because in the
PLC common point. I applied positive signal. The voltage rating of the photo
sensor is dc 12-24v but in the market here is amiable sensor which range is 24v -
240v ac / dc. There are available photo sensor are used by the project. It worked
 40
with metal sensor. When any type of metal come intro…. with a short range like 10
ml then sensor sensed & the contact will be open or closed depended on its
designed. There are amiable proximity sensor & switches different ranges like 10
ml, 5 ml in the market. Blue is 0v, brown > 24 dc, white >common, black >output
to make PNP.
3.5 Related device
3.5.1 PLC

Figure 3.5.1: PLC module

PLC is a digital computer [2] which is used for industrial automation. It is a special
form of microprocessor based controller, which uses a programmable memory to
store instructions and to implement functions such as logic, sequencing, timing,
counting, calculation, comparing and the processing of analog signals in order to
control machines & process. It is the replacement of conventional sequence system
such as electromechanical relays, timers. Basically a PLC operators by examining
the input signals connected from the process and carried out instruction on these
input signals, then it generates output signal to drive process equipment or
machinery. Standard inter faces are used in PLC, allow them to directly connect to
the process transducer or actuators without intermediate circuitry or relay.
CPU is the main part of the PLC. So that it called the ‘brain’ of the PLC. It consists
of a microprocessor for implementing the logic and controlling the
communications among the modules. It is designed so the designed circuit can be
entered in relay ladder logic form the processor accepts input data from various
sensing devices. Executes the stored user program and sends appropriate output
commands to control devices. Here we use LS ‘DR 30U’ model PLC which is
Master K120 series. It input power is 24 v dc, 7ma& output is 24 v dc/ 220 v ac
5A/7 A. It has 30 input output option where the input is 18 & the output number is
12. It is enabled with internal number 24vdc in the input side. So that we can use it
for test. It supported RS-232 serial ports for its communication. So that we can
 41
provide upload, download, monitoring & others many more functions. It
expandable with three input output card so that we can use it for a big application.
Like the others PLC it has also many more advantages like; easy to program, easy
maintenance, cost effective taster system response. higher reliability, low power
consumption can be checked with field devices etc. The name of programming
software of LS is ‘KGL WIN’ by using KGL WIN we can make program easily
and faster. And it is used for programming all LS or LG PLC except GOLFA.

3.5.2 Relay
A relay [3] is an electrically operated switch. Many relays use an electromagnet to
operate a switching mechanism, but other operating principles are used. Relays find
applications where it is necessary to control a circuit by a low-power signal or
where several circuits must be controlled by one signal. The first relays were used
in long distance telegraph circuits, repeating the signal coming in from one circuit
and re-transmitting it to another. Relays found extensive use in telephone
exchanges and early computers to perform logical operations. A type of relay that
can handle the high power required to directly drive an electric motor is called a
contractor. Solid-state relays control power circuits with no moving parts, instead
using a semiconductor device triggered by light to perform switching. Relays with
calibrated operating characteristics and sometimes multiple operating coils are used
to protect electrical circuits from overload or faults; in modern electric power
systems these functions are performed by digital instruments still called "protection
relays"on their function. The relay in the picture also has a wire connecting the
armature to the yoke. This ensures continuity of the circuit between the moving
contacts on the armature, and the circuit track on the printed circuit board (PCB)
via the yoke, which is soldered to the PCB. When an electric current is passed
through the coil, the resulting magnetic field attracts the armature and the
consequent movement of the movable contact or contacts either makes or breaks a
connection with a fixed contact. If the set of contacts was closed when the relay
was de-energized, then the movement opens the contacts and breaks the
connection, and vice versa if the contacts were open.
 42

Figure 3.5.2: Relay

When the current to the coil is switched off, the armature is returned by a force,
approximately half as strong as the magnetic force, to its relaxed position. Usually
this force is provided by a spring, but gravity is also used commonly in industrial
motor starters. Most relays are manufactured to operate quickly. In a low voltage
application, this is to reduce noise. In a high voltage or high current application,
this is to reduce arcing [4].
If the coil is energized with dc, a diode is frequently installed across the coil, to
dissipate the energy from the collapsing magnetic field at deactivation, which
would otherwise generate a voltage spike dangerous to circuit components. Some
automotive relays already include that diode inside the relay case. Alternatively a
contact protection network, consisting of a capacitor and resistor in series, may
absorb the surge. If the coil is designed to be energized with ac, a small copper ring
can be crimped to the end of the solenoid. This "shading ring" creates a small out-
of-phase current, which increases the minimum pull on the armature during the ac
cycle.
By analogy with the functions of the original electromagnetic device, a solid-state
relay is made with a thyristor or other solid-state switching device. To achieve
electrical isolation an opto coupler can be used which is a light-emitting diode
(LED) coupled with a photo transistor.

3.5.3 Switch

The electric is a device that is used for making, breaking or rerouting connection
in an electric circuit to operate the load. This switching is accomplished by the
opening or closing of two metal surfaces.
 43
Mainly switches are of three types:

a) Momentary action switch

b) Maintained action switch
c) Push PuII action switch

Momentary action switch:

When actuated power is applied to the switch. It changed its position, but if the
power is withdrawn, the switching position will be returned to the previous
position. This type of switch is called the momentary action switch. Example: Push
button switch, limit switch, level switch, pressure switch etc.

Maintained action switch:

When the actuated power is applied to the switch, it changes its position, but if the
power is withdrawn the switching position will remain unchanged. This type of
switch is called the maintained contact switch. Example: Normal on/off switch,
change over switch, toggle switch, slide switch etc.

Push-Pull action switch:

When the actuated power is applied to the switch, it changes its position, but if the
power is withdrawn the switches position will remain unchanged. If again the
power is applied, the switches position will returned to the previous position. This
type of switches called push pull action switch. Example: TV switch

Selector switch:

Which switch that we can select the NC or NO contact that called selector switch.
Normally it is two or three way But there is more way selector switch in the
market. When the actuated power is applied to the switch it changed its position,
but if the power is withdrawn, the switches position will remain unchanged. Only
we can change our position by another selector. Generally it has three positions-
Manual, Automatic & Stop.

3.5.4 Sensor
Two types of sensor are used, Such as:

(a) Photo electric sensor

 44

Figure 3.5.4(a) : Photo electric sensor

Electric represent perhaps the largest variety of problem solving choices in the
industrial sensor market. Today’s photoelectric technology has advanced to the
point where it is common to find a sensor that will detect a target less than 1mm in
diameter while other units have a sensing range up to 60 m. These factors make
them extremely adaptable in an endless array of applications. Although many
configurations are available including laser-based and fiber optic sensors. All photo
electric sensors consist of a few of basic components, Each contains an emitter,
which is a light source such as an LED(Light Emitting Diode)or laser diode, a
photodiode or phototransistor receiver to detect the light source, as well as the
supporting electronics designed to amplify the signal related from the receiver.
Probably the easiest way to describe the photoelectric operating principal is the
emitter, also referred to as the sender, transistors a beam of light either visible or
infrared, which is some fashion is directed to and detected by the receiver,
Although housings and designs are available they all seen to default to the basic
operating principal.

(b) Proximity sensor

Proximity sensors and switches use a reed switch and a permanent magnet. Each is
encased I a plastic housing for protection ease of mounting. A classic use is sensing
the opening of a door in a security system. A reed switch in the jamb and a
permanent magnet in the door complete a circuit when the door is closed. Opening
the door breaks the circuit.
 45

Figure 3.5.4(b) : Inductive proximity sensor

Figure3.5.4(c) : Inductive proximity sensor working

3.5.5 SMPS

Power supply is a [5] reference to a source electrical power. A device or system

that supplies electrical or other types of energy to an output load or group of loads
is called a power supply unit or PSU. The term is most commonly applied to
electrical energy supplies, less often to mechanical ones, and rarely to others. A
Switch Mode Power Supply (SMPS) works on a different principle, ac mains input
is directly rectified without the use of a transformer, to obtain a dc voltage. This
voltage is then sliced into small pieces by a high-speed electronic switch. The size
of these slices grows larger as power output requirements increase.
 46

Figure 3.5.5: Block diagram of a mains operated AC–DC SMPS with output
voltage regulation

3.5.6 DC Motor
A dc motor is designed to run on dc electric power [6]. Two examples of pure dc
designs are Michael Faraday's homo polar motor (which is uncommon), and the
ball bearing motor, which is (so far) a novelty. By far the most common dc motor
types are the brushed and brushless types, which use internal and external
commutation respectively to create an oscillating ac current from the dc source—so
they are not purely DC machines in a strict sense.

Figure 3.5.6: Structure of Permanent Magnet DC motor

Brushed DC Motor:

The classic dc motor design generates an oscillating current in a wound rotor, or

armature, with a split ring commutator , and either a wound or permanent magnet
 47
stator. A rotor consists of one or more coils of wire wound around a core on a

shaft; an electrical power source is connected to the rotor coil through the

commentator and its brushes [7], causing current to flow in it, producing

electromagnetism. The commentator causes the current in the coils to be switched

as the rotor turns, keeping the magnetic poles of the rotor from ever fully aligning

with the magnetic poles of the stator field, so that the rotor never stops (like a

compass needle does) but rather keeps rotating indefinitely (as long as power is

applied and is sufficient for the motor to overcome the shaft torque load and

internal losses due to friction, etc.)Many of the limitations of the classic

commutator DC motor are due to the need for brushes to press against the

commutator. This creates friction. At higher speeds, brushes have increasing

difficulty in maintaining contact. Brushes may bounce off the irregularities in the

commutator surface, creating sparks. (Sparks are also created inevitably by the

brushes making and breaking circuits through the rotor coils as the brushes cross

the insulating gaps between commutator sections. Depending on the commutator

design, this may include the brushes shorting together adjacent sections—and

hence coil ends—momentarily while crossing the gaps. Furthermore, the

inductance of the rotor coils causes the voltage across each to rise when its circuit

is opened, increasing the sparking of the brushes.) This sparking limits the

maximum speed of the machine, as too-rapid sparking will overheat, erode, or even

melt the commentator. The current density per unit area of the brushes, in

combination with their resistivity, limits the output of the motor. The making and

breaking of electric contact also causes electrical noise, and the sparks additionally
 48
cause RFI. Brushes eventually wear out and require replacement, and the

commentator itself is subject to wear and maintenance (on larger motors) or

replacement (on small motors). The commentator assembly on a large machine is a

costly element, requiring precision assembly of many parts. On small motors, the

commutator is usually permanently integrated into the rotor, so replacing it usually

requires replacing the whole rotor.

Large brushes are desired for a larger brush contact area to maximize motor output,
but small brushes are desired for low mass to maximize the speed at which the
motor can run without the brushes excessively bouncing and sparking (comparable
to the problem of "valve float" in internal combustion engines). (Small brushes are
also desirable for lower cost). Stiffer brush springs can also be used to make
brushes of a given mass work at a higher speed, but at the cost of greater friction
losses (lower efficiency) and accelerated brush and commutator wear. Therefore,
dc motor brush design entails a trade-off between output power, speed, and
efficiency/wear.
Brushless DC motor:
Brushless dc motors are commonly used where precise speed control is necessary,
as in computer disk drives or in video cassette recorders, the spindles within CD,
CD-ROM etc. Drives, and mechanisms within office products such as fans, laser
printers and photocopiers. They have several advantages over conventional motors.
Compared to ac fans using shaded-pole motors, they are very efficient, running
much cooler than the equivalent ac motors. This cool operation leads to much-
improved life of the fan's bearings.
Without a commutator to wear out, the life of a DC brushless motor can be
significantly longer compared to a dc motor using brushes and a commutator.
Commutation also tends to cause a great deal of electrical and RF noise; without a
commentator or brushes, a brushless motor may be used in electrically sensitive
devices like audio equipment or computers .The same hall effect sensors that
provide the commutation can also provide a convenient tachometer signal for
closed-loop control (servo-controlled) applications. In fans, the tachometer signal
can be used to derive a "fan ok" signal.

 The motor can be easily synchronized to an internal or external clock,

leading to precise speed control.
 Brushless motors have no chance of sparking, unlike brushed motors,
making them better suited to environments with volatile chemicals and fuels.
Also, sparking generates ozone which can accumulate in poorly ventilated
buildings risking harm to occupants' health.
 49
 Brushless motors are usually used in small equipment such as computers and
are generally used to get rid of unwanted heat.
 They are also very quiet motors which is an advantage if being used in
equipment that is affected by vibrations.

Modern dc brushless motors range in power from a fraction of a watt to many

kilowatts. Larger brushless motors up to about 100 kw rating are used in electric
vehicles. They also find significant use in high-performance electric model aircraft.
Coreless or Ironless DC Motor:
Nothing in the design of any motors described above requires that the iron (steel)
portions of the rotor actually rotate; torque is exerted only on the windings of the
electromagnets. Taking advantage of this fact is the coreless or ironless dc motor, a
specialized form of a brush or brushless dc motor. Optimized for rapid
acceleration, these motors have a rotor that is constructed without any iron core.
The rotor can take the form of a winding-filled cylinder, or a self-supporting
structure comprising only the magnet wire and the bonding material. The rotor can
fit inside the stator magnets; a magnetically-soft stationary cylinder inside the rotor
provides a return path for the stator magnetic flux. A second arrangement has the
rotor winding basket surrounding the stator magnets.
In that design, the rotor fits inside a magnetically-soft cylinder that can
serve as the housing for the motor, and likewise provides a return path for the flux.
A third design has the windings shaped as a disc (originally formed on a printed
circuit board) running between arrays of high-flux magnets facing the rotor and
arranged in a circle. This design is commonly known either as the printed motor or
the pancake motor because of its extremely flat profile. The armature in a printed
motor is made from punched copper sheets that are laminated together using
advanced composites to form a rigid disc onto which a hub can be bonded .The
windings are typically stabilized by being impregnated with electrical epoxy
potting systems.
These are filled epoxies that have moderate mixed viscosity and a long get
time. They are highlighted by low shrinkage and low exothermic, and are typically
UL 1446 recognized as a potting compound for use up to 180°C (Class H) (UL file
No. E 210549).Because the rotor is much lighter in weight (mass) than a
 50
conventional rotor formed from copper windings on steel laminations, the
rotor can accelerate much more rapidly, often achieving a mechanical time constant
under 1 m s. This is especially true if the windings use aluminum rather than the
heavier copper. But because there is no metal mass in the rotor to act as a heat sink,
even small coreless motors must often be cooled by forced air. Another advantage
of ironless dc motors is that there is no cogging (vibration caused by attraction
between the iron and the magnets) and parasitic eddy currents cannot form in the
iron. This can greatly improve efficiency, but variable-speed controllers must use a
significantly higher switching rate (>150 kHz) or direct current because of the
decreased electromagnetic induction .These motors were commonly used to drive
the capstan(s) of magnetic tape drives and are still widely used in high-
performance servo-controlled systems, like radio-controlled vehicles/aircraft,
humanoid robotic systems, industrial automation, medical devices, etc. Related
limited-travel actuators have no core and a bonded coil placed between the poles of
high-flux thin permanent magnets. These are the fast head positioned for rigid-disk
"hard disk" drives [8].
3.6 PLC Connection

Fwd. Rev P.S-1 P.S-2 Pr.S-1 Pr.S-2 P.S-3

select select

+ - 24v dc
SMPS
P00 P02 P04 P06 P08 COM 1 P0B P0D P0F P11 P13 P15 COM0

P01 P03 P05 P07 P09 P0A P0C P0E P10 P12 P14 24VG 24V

Input: 24 V DC 7mA
K7M-DR40U PLC

Output: 24V DC/ 220 AC 2A/P 5A/C

AC 100-240 V
P40 P41 P42 . P44 P46 . P48 P4A . P4C P4B

FG COM0 COM1 COM2 P43 COM3 P45 P47 COM4 P49 P4B COM5 P4D P4E P4F

Fwd. Rev
M1 (Rev.) M2 (Rev.) M3 (Up) M2 (Fwd) M3 (Dn) M4 (Fwd) M4 (Rev) M1(Fwd)
select Select

Figure 3.6: Block diagram with input output connection

If we want to make PLC connection, we should take necessary steps which are given
bellow:

a) Through a 220v ac power supply from any source on our PLC to activate it.

b) We should make a communication between PC to PLC for upload, download, start,

monitoring & many more by using RS-232 serial port or RS-485.

c) To excited the internal relay of the PLC, at first we need to select the common
signal of the PLC which are in the input side. If the common signal is 24v dc positive,
then the signals which are comes from the field side & connect as an input signal, will
must be 24v dc common. So that relay will be excited & its auxiliary contact, which
are given in the output side will changed.
d) To operate the load by using auxiliary contacts of the PLC, which are given in the
output side, we should select the output common signal. If the common signal will
positive then another signal which will connect with load will must be negative.
Normally 24v dc or 220v ac are used as output signal.

3.7 Advantage
PLC is a digital computer for the industrial automation. Now days it is widely used for
the automation of industrial application for its amazing advantages like:

1. Higher reliability
2. Available monitoring facility
3. Cost effective
4. Easy maintenance
5. Can be checked without any field devices
6. Can interface with computer
7. Compact in construction
8. Low power consumption
Chapter 4
Software and Programming
4.1 Introduction
An instruction is a symbol or a group of letters, which initiates the PLC to perform a
specific function. A set or a group of predetermined instructions, which activates the
PLC to execute desired sequential operations, is known as program.
The instructions used for microprocessor based system is known as the language for
the system is. Now a days, different types of high level languages and available for
programming PLC, which provides commands & statements very close to the actual
functions, programs for microprocessor based systems to be loaded into the machine
code, this beings a sequence of binary numbers to represent the program
instructions.However, assembly language is based on the use of mnemonics & a
computer program called an assembler is to translate the mnemonics into machine
code.
4.2 Programming language
Program can be made even easier by the use of so called high level languages such as
C, BASIC, PASCAL, FORTRAN etc. Thus need of prepackaged functions
represented by simple words or symbols descriptive of the function concerned.
However, the use of these methods to write the PLC programs requires some skill in
programming and PLCs are intended to be use by engineers without any great
knowledge of programming.
As a consequence, different programming languages are developed. This is a means of
writing program instructions, which can convert into the machine code by some
software or compiler used for a particular language.
Different PLCs have different programming facilities. Some PLC accept one
language, but some PLCs accept more than one language . The widely used
programming languages for PLCs are :
a) Ladder Diagram
b) Instruction Code
c) Logic Circuit
d) Sequential Function Chart(SFC)

4.3 Ladder Diagram:

This is a very commonly used language of programming PLCs is based on the use of
ladder diagrams. In this language, different types of symbol, which are similar to hand
warred relay ladder circuit, are used to develop this program. The ladder diagram
consist of two vertical lines representing the power rails, circuits are connected as
horizontal lines (The rung of the ladder between two verticals).
In Ladder diagram, the following conventions are followed:
1. The vertical lines of the diagram represent the power rails between which circuits
are connect.
2. Each rung of the ladder defines one operation in control process.
3. It read from left to right & from top to bottom.
4. Each rung must start with an input or inputs and must end with at least one output.
5. Electrical devices are shown in their normal condition.
6. A particular device can appear in more than one rung of a ladder.
4.4 KGL WIN

Figure 4.4: KGL WIN

4.4.1 Feature
In the project we use LS PLC, KGL- WIN its programming software & debugging
tool for LS/LG Master-K series and KGL abundant features as bellow: [9]
 Program compatible between LG Master –K
series: A user can use the program created in LG Master-K series for the
Program created in other in LG Master-K series as well. The Program,
Parameter or Variable / Comment created in KGL-DOS or GSI KGL can be
also used in KGL WIN.
 PLC System configuration by project structure:
KGL WIN manages the user defined program as one the project including the
parameter and variable / comment. Also a user can save a program, parameter,
variable or comment respectively and the stored each file can be used for other
project files.
 User friendly interface: Easy and useful interface
for Creating, Editing & Monitoring.
 Online Editing: A real time Editing is available in
online made the program edited in the online condition can be downloaded
automatically without stopping PLC hardware.
 Monitoring the information from PLC: A user can
easily monitor PLC status such as error status, network information & system
status.
 Communication cable: LS/LG PLC support RS-
232 interface for local connection. It also supports RS-485. By using RS-232
serial port or RS-485 we can communicate LS / LG PLC with PC for creating,
monitoring, upload, download & many more.

4.4.2 System requirement

To installation KGL WIN we need following need on our pc which is given bellow:
1. IBM compatible and memory (RAM) 80486 DX
or greater, 8 Mb RAM or more.
2. Serial port: RS-232 or RS-485 serial port.
3. 20 Mb or harder disk.
4. One or more (3.5 inch or 5.25 inch) floppy disk
drive.
5. Compatible with windows 95/98 mouse and
printer. Microsoft windows 95/98 system
4.4.3 Installation:
System requirement - To installation KGL WIN we need following pc which is
given bellow:
6. IBM compatible and memory (RAM) 80486 DX
or greater, 8 Mb RAM or more.
7. Serial port: RS-232 or RS-485 serial port.
8. 20 Mb or harder disk.
9. One or more (3.5 inch or 5.25 inch) floppy disk
drive.
10. Compatible with windows 95/98 mouse and
printer.
11. Microsoft windows 95/98 system.

4.4.4 Communication cable

LS/LG PLC support RS- 232 interface for local connection. It also supports RS-485.
By using RS-232 serial port or RS-485 we can communicate LS / LG PLC with PC
for creating, monitoring, upload, download & many more.

4.4.5 Symbols
KGL WINDOWS SYMBOL : The symbol who’s are normally available used that
are given bellow:
Symbol-1:

Arrow
Symbol-2:

Normally open input contact or examine ‘ON’

Symbol-3:

Normally close input contacts or examine ‘OFF’

Symbol-4:

Horizontal line for creating a Rung

Symbol-5:

Vertical line
Symbol-6:

Output device or output coil

Symbol-7:

Applied instruction for using timer, counter, END& others

Symbol-8:

Not instruction

Symbol-9:

Zoom in

Symbol-10:

Zoom out

Symbol-11:

Showing in details
Symbol-12:

Decrease the number of column.

Symbol-13:

Mnemonic

Symbol-14:

Device Reference

Symbol-15:

Used I/O

Symbol-16:

Device

Symbol-17:

Variable if we check symbol we can see variable name instead of device name.

Symbol-18:

Device+ Variable
Symbol-19:

Device+ Comments

Symbol-20: Connect.

When we click here the PLC will connect with pc.

Symbol-21: Connect+ Download+ Run+ Monitor start.

Symbol-22: Run.

When the program will stop just press it for run it again & monitoring the status of
PLC.
Symbol-23: Stop.

When we need stop just press it for run it.

Symbol-24: New project.

In the new project here are blank project, create project from files.

Symbol-25: Project open.

To open any saved project press it and find the expected files.

Symbol-26: Project save.

To save the create project click here.

Symbol-27: New.

To change the old or create a new program , variable & comment or parameter just
press it & full fill the requirements.

Symbol-28:

Symbol-29: Find.

To find any string click here &type your find string.

Symbol-30: Replace.

To replace any string press it, find your string, make new string click ‘ok’. In
dialogue box for replace string.

Symbol-31: Help topics.

For windows help& supports press it.

Symbol-32: Help

Symbol-33: Print.

If you want to print your program, open your program ,click here& full fill the
requirements.
Symbol-34: Cut.

Symbol-35: Copy

Symbol-36: Paste

Symbol-37: Pause

Symbol-38: (L) OR (S)

Latch or set (latched used with Unlatched)

Symbol-39: (U) OR (R)

Unlatch or reset (and set used with reset)

Symbol-40: (RST) OR (/)

Reset/De-energize output/coil de-energize.

Symbol-41: [PLS]

Generate pulse /coil energize for single scan.

Symbol-42: (/ ) or ( )

Generate pulse at rising input.

Symbol-43:

Generate pulse at dropping input.

Retentive on delay timer

Symbol-45:

Retentive off delay timer

Symbol-46:

Input in parallel connection

Symbol-47:

Up counter

Symbol-48:

Down counter

Symbol-49:
Branch open

Symbol-50:

Branch close

4.5 Application
4.5.1 Creating a project:
1. Double click KGL_WE exe file to run KGL WIN.
2. The startup screen will be shown.
3. To create a new project, select project > New project>start up screen.
4. Select blank project in the dialogue box and click ‘ok’ button’.
5. In the following dialogue box, type in PLC type, programming language, title
company, author & description.
6. Click ‘OK’ button then project, message& program windows displayed
automatically.

We can also create new using already created files from KGL-DOS or GSIKGL as
well as KGL WIN.
4.5.2 Creating a program
For creating a ladder program we can choose your tools or contact like normally
open -()-, Normally close –()-,Horizontal(-),or vertical bar. According to your circuit
diagram. After selecting your tools from ladder diagram, move the cursor to the
place to insert the contact. Click the left button of the mouse or press ’Enter key’. The
contact name of the device and press ’ok’ button. You can add more devices as per
need your circuit diagram & finally select the output coil – ( )- which is in right side
to finish an output when you select it & insert it into ladder wind. Then shows a
dialogue box again for typing output address type an address & pressed ‘ok’ or enter
key. Thus you can add another may as per your needed & finally when your ladder
will finished according to your drawing. You should must insert END line at the end
of your ladder. Thus you can make a program. You can find many more option in the
applied instruction tools.
4.5.3 Upload & down load
For upload your program from PLC to your PC at first you should make
communication from PC to PLC by using RS-232 serial port & through a 220v ac
Power in your PLC to PC ……then you should find out the ‘online’ from the ladder
tool loan…. windows. Select the online then you can find a dialog box. Click the
‘connect’ for communication the PLC with PC. Then you enter …. Find here ‘Read
KGL WIN’ on online mode. Click it. Then the upload will start processing when the
processing will finish just click ‘ok’ bottom. The program which was on your PLC is
be uploaded your PC.
For download the program at first you should communicate the PC with your PLC.
Then through 220v ac power support in your PLC to activate it. Then find out ‘online’
from your ladder tool bars windows. Select ‘online’ you can see a dialog box & also
see the ‘connect+ Run+ Monitor+ Download ‘in here press it. Then your download
process will be start. When it finished, Press on button. You thus your program will
down loaded your PLC. You can also download the program just click the download
symbol from your ladder toolbar directly.

4.5.4 Online Edit

This function is performed only when the verification is completed and in the
monitoring mode. In this mode, you may not execute the download function after
editing. It will be load automatically.
 The Program is changed automatically without the mode changing into stop
mode. So you must be carefully when you do edit the Program in the online
mode.
 In order to edit the program move the cursor on the instruction that you want to
change & double click or press ‘Enter’ key. Click ‘OK’ button.
 The message box to continue the change will appear below.
Click ‘ok’ button to complete the online edit
 To complete online edit, chick ok button in Message box for confirm

4.5.5 Variable / Comment

In order to input Variable / Comment
 Select Variable / comment in project window.
 If you double click Variable / Comment, Variable / Comment window is
append.
 If you press enter key on double – click, variable / comment edit box is
appended.
 In Variable / Comment edit window, input device name, variable / comment &
click ok button.
  Check the ‘Edit next device often saving connect device, the Variable /
Comment edit windows for next device will automatically.

4.5.6 Monitoring
To monitor the PLC devices or system Information, select monitor in the project
window.
 After selecting the type of devices to monitor, enter device name & number.
 If you want to monitor hugs, you can choose flags in the following combo box
after selecting the device.

We can monitor other details information such as PLC information,

Information link information & above.
 To monitor the current condition if the ladder of PLC after it connected
with PC. At first you should through a power supply (AC 220V) to activated the
PLC then you should make communication from PC to PLC by using RS-232
serial port. Select the KGL WIN windows. Then
1. Select ‘online’
2. Select ‘connect’
3. Select ‘monitor start.’

Then the ladder diagram which was in the PLC memory is appeared it also show the
current status of PLC.
4.5.7 Save the project
To save the project created in the along
 Select ‘Project’
 Save project in the pull down menu.
 Enter the project name (Test pry) to save the active. If you don’t enter the name,
the project will be saved as new project.
 (Window comments) are stored in the project including the status of the
window arrangement.

4.5.8 Menu
 To perform an item (command) in Menu, you can select the command in pull
down menu on the icon in the speed bar.
 The menu bar provides two ways to on we to access the pull down menus
…….. Appeals, we can access the menu items in the same ways by either using
the mouse or pressing the undelivered letter (project)….

In order to execute commands by the underlined character in the menu list.

Press the <ALT> key first and then press the letter.
The various types of menu are given below:
Project:
Commands Description
New Project Create a new project
Open project Open an existing project
Save project Save an active project
Save project as Save the active project as new project
Close project Close the current project
Binary file Load / make binary file
Save Item Save program, parameter & variable comment as files
load item Load program, parameter & variable comments file in
…..
Option Set KGL WIN option
Print Print the active document
Print Preview Preview documents to print
Print setup Setup the printer options
Recent Project Open the recent project
Exit Quite the application
Connect+ Download + Execute transfer Run & Monitor function
Monitor + start + Run simultaneously
Connect Connect to PLC
Disconnect Disconnect from PLC
Monitor start Start Monitoring
Mode change
Mode change Run Change PLC mode to run
Stop Change PLC mode to stop
Pause Change PLC mode to pause
Debug Change PLC mode to debug
Read System Monitor ON / OFF status of I/O module
Information monitor
PLC Show PLC type, version, memory pack.
Information
I/O Show type of modules & O/S version number
Information
Link Show the shot number of network mode
Information
Information Show the slot number of M net module
High Speed Monitor Hi speed link parameter
link
parameter
 Write Set PLC Set PLC clock
Information clock
Change Change the password in PLC
password

4.6 Instruction
4.6.1 Timer Instruction
Timer may be on –delay or off- delay. Each of these two may be either retentive &
non-retentive. There may be another type of timer known as on- off delay.Following
are the example of on-delay, Non-retentive timer. If input addresses P0:1 becomes on,
then timer start to count time (just like a stop watch). Time counting remains
continuing until address P0:1 becomes off. If P0: 1 becomes off then timer counting
value reset to zero (During energizing period of P0:1 if timer reaches to its maximum
value, then it starts counting from zero again).If counting value reaches at 100 units
(for this example) of time. The set point, then address to become on. If P0:1 becomes
off any time. Then address to become of instantly.
P0:1
T ON T0,100
Switch-1 P1:0

T0 Lamp 0
END

P0:0
TA ON T1,100
Switch-0 P1:1
T1 Lamp 1
END

In above figure T0, T1 etc. address of timers. TON,

TAON indicate different time functions. One unit of time may be 0.1 second, 0.01
second etc depending on different time functions. Representation of different time
functions may be done by different symbols like on d tr (On-delay timer), of d tr (off-
delay timer),TIM, T,TON,TOFF,RTF or any other symbols depends on manufacturers
choice. Here is another example of off- delay, non retentive timer. Here if address
P0:1 becomes on then timer starts counting time and when counting value reaches at
100 unit of time then address’ TO’ becomes off.
 P0:1
T OFF T0,100
Switch-1 P1:0
T0 Lamp 0
END

P0:0
TA OFF T1,100
Switch-0 P1:1
T1 Lamp 1
END

The following figure shows an example of retentive on-delay timer. It address

101becomes energize and remains energize for 10.0 unit of time, and then address 901
will be energized. But it will not be de-energized unless address 102 is energized.
Most of the cases, Timer counts timing during the period of energizing of address 101
and it stops at standstill during de-energizing period of address101.Time counting
goes to zero value at energizing of address 101and it continue irrespective of 101
remains energizing or de-energizing until 102 is energized.

101 901
RT0

901 PR=10.0
111
102 901
RST

The following figure shows an application of a retentive off-delay timer. Timer

address 902 becomes energized instantly at the time of energizing of address103.It de-
energizing time of 103.But 902 does not re-energize at the time of energizing of 103
until 104 energized to reset the timing value at zero.
 103 902
PR=90.0
104 902
RST
902
112

Note that when both of timing address (here 101 or 103) and reset address (here102 or 104)
because energize the reset address over rides the timing address. Now days, most of the
manufacturers represent the timer instruction by a functional block diagram like bellow:

Q0200
10100 2
on d tmr-tenths
PV=500
10101 PV=500
PV=500
R
PV
R0200
PV=50

On d timer: Tenths indicates the type of timer and unit of time that it counts. Here timer is
retentive on-delay. It counting unit of time is 0.1 sec (tenths).If input address 10100 becomes
energize then timer start counting time. Register R0200 contains the instantaneous value of
time. When this value crosses PV value (Here 500 unit of time i.e. 50.0 seconds) then output
Q02002 becomes energize and remains energize until 10101 becomes energized.(There is
no reset input for non-retentive timer). The maximum value that a timer can count is
predetermined by its manufacture.
4.6.2 Counter Instruction
Counter instruction is similar to retentive timer instruction; except that timer counts time, but
counter counts events i.e. number of pulses. There are two types of counter, one is up –
counter that counts the pulse from zero to upward maximum value and other is down-counter
that counts the pulses from a preset value to download zero. The maximum value that a
counter can count is predetermined by its manufacture. Normally this value is 32768 for a 16
bit processor and 65535 for a 32 bit processor. A counter address is normally represented by
a letter ’C’ follows with a number.
In the following example, CTU indicates up counter, CO is the address of the counter (single
bit address) and 10 is the preset value (PV). If P0:0 is energized 10 times then the address
CO will be energized. If P0:1 is energized then CO will be reset to zero.
 P0:0
C
Switch0
P0:1 R
Switch1

C0 P1:0

Lamp0

EN

In the following figure, if address P: 1 is energized then counting value reset to 10.After this
it address P0:0 is energized 10 times then address ‘C1’ becomes energized.
P0:0
C
Switch0
P0:1 R
Switch1

C1 P1:0

Lamp1

END

Now a day’s most of the manufactures represent the counter instruction by a block diagram
like bellow:

1010
Upcounter
PV=500
1010 Q0200
R020

If input address 10100 becomes energized. Resister R0200 contains the instantaneous
value of numbers of pulse. When 10101 is energized, Then Q02002 becomes de-energized
and contains of R0200 becomes 0(zero).

4.7 Using Ladder diagram and description

4.7.1 Ladder Diagram
P0000 P0040
0 Fwd mode select
Fwd select

P0001 P0040 P0041

2 Fwd Rev mode select
Rev select
mode select
P0040 P0002 P0049 P0042
5
Photo Down Conv. Motor (M1)
Fwd sensor 1 Conv. Motor
mode select P0004

Proximity sensor 1

P0041 P0045 P0042 P0049

11
Lift Conv. Conv. Down
Rev
Motor (M2) Conv. motor
mode select Motor (M1)
P0002

Photo sensor 1

P0040 P0003 P0004 P0045 P0044 P0043

17
Fwd Photo Proximity Lift Conv. Lift Lift Conv.
mode select sensor 2 sensor 1 Motor (M2) Motor (M3) Motor (M2)
P0041 P0003 P0005

Rev Photo Proximity

mode select sensor 2 sensor 2

P0040 P0003 P0005 P0046 P0006 P0044

27
Fwd Photo Proximity Lift Photo
sensor 2 sensor 2 Lift
mode select Motor (M3) sensor 3
Motor (M3)
P0044
Lift
Motor (M3)

P0041 P0002

Rev Photo
sensor 1
mode select
P0044
 P0040 P0005 P0006 P0003 P0043 P0045
40
Photo
Fwd mode
Proximity-2 Photo sensor-2 Lift Conv. Lift Conv.
selector Motor 3
sensor-3 Motor M3
P0045

P0041 P0004 P0002 P0003

Rev mode Photo

Photo sensor-2
selector Proximity-1 sensor-1
P0045

Lift Conv. Motor 3

P004 P000 P000 P004 P004
0 6 4 4 6
55
Fwd mode Photo Lift
Lift
Proximity
selector sensor-3 sensor-1 Motor-3
Motor-3
P004
6

Lift Conv.
Motor 3
P004 P000
1 3

Rev mode Photo

sensor-2
selector
P004
6

Lift Conv. Motor 3

P004 P004 P004 P004
0 5 8 7
67
Lift Conv. Up Conv. Up Conv.
Fwd mode
Motor 2
selector Motor M-4 MotorM-4
P000
6

Photo sensor-3
P004 P000 P004
P004
1 6 7
73 8

Rev mode Photo Up Conv. Up Conv.

selector sensor-3 Motor M-4 Motor M-4

P000
5
Proximity
sensor-2

79 END
4.7.2 Description of the Ladder Diagram.

In PLC based lift automation system I use LG branded MASTER-K 120S series PLC.
This type of PLC the user software name is KGL-WE. The project has both forward
(P0040) &reverse (P0041) mode which is selected by a three way selector switch. The
three way of the selector are forward (P0000), reverse (P0001 ) & stop .In forward
mode the lift will caring the product from down conveyor to up conveyor & in
reverse mode the lift will caring the product from up conveyor to down conveyor &
in reverse mode it will caring the product from up conveyor to down conveyor .

When you select the forward mode (P0040) by using right side of the selector (P0000)
switch, the lift will stay at the down conveyor position & it will waiting for the
product. At this position the down proximity (P0004) will get contact & it gives the
controlling commands to the lift conveyor (P0043) & down conveyor (P0042) for run
with anticlockwise rotation. So that the loading procedure will be started & the
product will be loaded into the lift. when the lift conveyor sensor (P0003) sensed it,
then it will gives the controlling commands for stop the lift conveyor motor (P0043)
& start the lift caring motor (P0044) with clockwise rotation, so that the lift will
caring the product .

Thus the lift conveyor sensor (P0003) stopped the loading procedure & start the
caring procedure . When the lift will going for up it will stopped by the upper
proximity (P0005), when it sensed. Normally it is situated in the upper conveyor
position, so that the product can be unloading by using upper conveyor. When the
upper proximity get contacted, it will stop the caring & start the lift conveyor motor
(P0045) & the upper conveyor motor (P0047) with clockwise rotation .

So that the product can be unloaded by using the conveyors. when it sensed the upper
conveyor photo sensor (P0046), it will stopped the lift conveyor (P0045) & gives the
controlling commands for start the lift caring motor (P0046) in anticlockwise rotation
,so that the lift will go back & can wait for the next product .Thus a cycle will be
completed .
Inversely, when you select the reverse mode (P0041), the lift will carry the product
from up conveyor to down conveyor position. Here are enough safety in the ladder
diagram to prevent friction like - when the lift will up ,the next product will stopped
by the down conveyor sensor(P0001), when it sensed (In forward mode) .

When the lift will go back, the product will be stopped by up conveyor sensor (P0006)
in reverse mode .so that the product can not fall down from the conveyor & can’t be
damaged. When the product is in up conveyor position .It can’t allowed the lift to
going up with product & thus it prevent friction with one product to another product.
Chapter 5
Performance Test
5.1 Introduction
This lift project is fully automatically system for product loading, carrying &
unloading procedure. For automation of the project. I used here latest, intelligent PLC
instrument which have heavy performance and amazing advantages like;
a)High reliability
b) Cost effective
c) Faster system response
d)Easy to program& maintenance
e) More accuracy
f) Noiseless performance
g) Available monitoring facility
h) Low power consumption
i) Compact in construction
j) Can interface with computer
k) Can be checked without any field device.
5.2 Performance

For its high performance facilities it is widely used in different industrial plant as a
‘Industrial Computer’ for automation of industrial processes. Here are four DC motors
with gearbox. Three of them are for conveyor & one is for carrying the lift. These
motors are low power consumption (100w, 24vdc) but high powerfully & the gearbox
increases its power. The lift & the conveyors run smoothly with more reliability for
using gearbox type motor. Here I use eight relays for switching the four motors to
prevent the short circuit of the motor when they will run with both clock&
anticlockwise rotation, uses five sensors are set well their best position & in the
program, Here are enough safety to avoid any kind of friction.

Here I used a power supply unit which is 220v ac to24v dc &switching mode type. It
can break easily by cut its own fuse when any short circuit will occur. Here I used
five sensors, two of them are proximity type & need not to be clean & it works with
long(10 mm maximum ranges) distances. The both modes are fully separated from
one with another by using a three way selector switch. Although there is a little bit of
structural problem, therefore we can say easily that the performance of the project is
very good &it can run continuously for a long time without any disturbance or
maintenance.
Chapter 6
Discussion and Conclusion

6.1 Conclusion

The main objectives of this project are to design and construction a PLC
(Programmable Logic Controller) based lift automation system to loading, carrying
and unloading the refrigerator in industry / firms. From theoretical and practical
results previous chapter following conclusions can be made:

1. A good arrangement between the experimental setup and the theoretical model
suggested that the constructed PLC (Programmable Logic Controller) based lift
automation system is accurate enough.

2. The refrigerator loading by the conveyor, carrying by lift conveyor and

unloading the conveyor automatically controlling by PLC (Programmable
Logic Controller) control.

3. The project runs properly in specified time and speed, etc.

6.2 Future Enhancement
The lift is a ‘PLC’ based fully automation project which can carry man, goods or
anything from one floor to another floor. We can use it easily in any home, industries,
shopping mall & others where are high rise building or tower, at least more than one
floor. By using of PLC the project makes more attractive, alive & reliable. It has many
more amazing features & advantages. It is widely used in different industrial plant as a
‘Industrial computer’ for industrial processes. By using the project we can carry any
goods from down floor to up floor or down production line to up production line
which is available in high rise industries. Inversely we can carry the product from up
production line to down production line.
Because it has both forward& reverse mode. Its making, Installation & maintenance
cost is too low but its performance is very high. It can run continuously without any
maintenance and disturbance for a long time. And it is easily possible to make any
addition or correction of the function without any hard ware changes. If we need we
can easily include any more option on it using via software. Now a days it can use any
building or shopping mall where are more than one floor. But in future if may needed
some options like;
1. Calling system from any floor.
2. Adjustable with high rise building.
3. Automatic door open or close of the lift.
4. Display the status of current floor.
It saves time, money, and worker and worked more reliable, speedy, noiseless
environment. It also avoids all kinds of friction& accidents.
 REFERENCES

[1] http://en.wikipedia.org/wiki/Conveyor.
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[3] Mason, C. R., Art & Science of Protective Relaying, Chapter 2, GE Consumer &
Electrical.
[4] Gurevich, Vladimir (2005). Electrical Relays: Principles and Applications. London
New York: CRC Press.
[5] Harpit Singh Sandhu, Running Small Motors with PIC Microcontrollers, The Mc-
Graw Hill Companies, 2008, ISBN: 978-0-07-163362-9
[6] Kenneth B. Rexford and Peter R. Giuliani (2002). Electrical control for machines
(6th ed.). Engage Learning. p. 58. ISBN 9780766861985.
[7] B.L.Theraja, A textbook of Electrical Technology, volume II(AC & DC machines),
ISBN: 81-219-1142-7
[8] Cyril W. Lander, Power Electronics 3rd Edition, Mc Graw Hill International UK
Limited, London 1993 ISBN 0-07-707714-8 Chapter 9-8 Slip Ring Induction Motor
Control
[9] MASTER-K-120S series PLC Manual from LG Electronics
[10] Walter A. Elmore. Protective Relaying Theory and Applications. Marcel Dekker,
Inc.. ISBN 0-8247-9152-5.