Prem Project Report PLC Final Traffic - 1

Controlling of Traffic signal light using PLC 2022-23
ABSTRACT
Control Engineering has evolved over time. In the past humans were the main methods
for controlling a system. More recently electricity has been used for control and early electrical
control was based on relays. These relays allow power to be switched on and off without a
mechanical switch. It is common to use relays to make simple logical control decisions. The
development of low cost computer has brought the most recent revolution, the Programmable
Logic Controller (PLC). The arrival of the PLC began in the 1970s and has become the most
common choice for manufacturing controls. PLCs have been gaining popularity on the factory
floor and will probably remain predominant for some time to come.
PLCs are most certain for all mechanical engineers. Students studying in this stream
have to acquire a basic knowledge about automation. Recently, Board of Technical Education
(DTE) prescribed “Elements of Automation” course for 4th semester students’ in new C20
curriculum. In this regard, to make laboratory setup for junior friends, an attempt is made to
design and fabricate student friendly and safe PLC kits is undertaken. This project helps to
understand the automation concepts by easily by designing any conceived automation idea and
downloading to PLC. "Elevator Model" is also designed and fabricated to interface with PLCs.
Students can individually program and download any logic to control elevator model according
his conceived logic.
In this kits, latest and industry 2.0 recommended Allen Bradley's Micro820 PLC is
used. Most common programming method, Ladder Logic is used to program the PLC. Most
recent push buttons, sensors, motors, relay, solenoids and displays are used to make the models
more realistic
DME SJEP Govt. Polytechnic Bangalore - 560001 1

ACNOWLEDGEMENTS
We have great pleasure in expressing our deep sense of gratitude to this institution,
which as provided us an opportunity to do the project in the college and also facilities for doing
it.
We are grateful to Smt, GAYATHRI V Principal, and Sri, HARISH KUMAR S V,

Head of Mechanical Engineering Department, for their inspiration and help for doing this
project.
We whole heatedly thank all staff members of Mechanical Engineering Department for
their suggestions and support.
We thank staff member of Government Polytechnic, Holenarasipura for extending their

support to fabricate PLC trainer kit frame.
Last but the least, we also thank all those who have been directly or indirectly involved
in the completion of our project.

CONTENTS
Chapter 1: Introduction to Programmable Logic Controller Page No

1.1 Introduction 01-05
1.2 History 06-07
1.3 Components of PLC 07-08
1.4 Basic Structure of Programmable Logic Controller 09-09
1.5 Input/ Output 10-10
1.6 Input/ Output Processing 11-12
1.7 Ladder Logic 12-19
1.8 Timer, Internal Relay and Counters 19-24
1.9 Manufacturing and Assembly Process 25-25
1.10 Merits and Demerits of Automation 25-27
Chapter 2: Design and Implementation of a PLC Trainer Workstation 28-34

2.1 Structure of PLC Trainer Workstation 28-29
2.2 Aluminum Frame 29-31
2.3 Programmable Logic Controller (PLC) 31-32
2.4 PLC Programming Software 33-33
2.5 Power Supply 34-34
Chapter 3: Fabrication of traffic light signal model 35-44

3.1 Introduction 36-38
3.2 Structure of Traffic light signal model 39-42
3.3 Traffic light signal ladder diagram 42-44
Chapter 4: Estimation and Costing 45-47

4.1 Estimation and Costing 46-47
Chapter 5: Conclusions 48-49
References 50-50

CHAPTER 1
INTRODUCTION TO PROGRAMMABLE LOGIC
CONTROLLERS

CHAPTER 1:
PROGRAMMABLE LOGIC CONTROLLER
1.1 INTRODUCTION:
A programmable logic controller, PLC, or programmable controller is a small computer
used for automation of real-world processes, such as control of machinery on factory assembly
lines. The PLC usually uses a microprocessor. The program can often control complex
sequencing and is written by skilled engineers. The program is stored in battery-backed memory
and/or EEPROMs.
PLCs differ from normal computers by its special input/output arrangements. These
connect the PLC to sensors and actuators. PLCs read limit switches, dual-level devices,
temperature indicators and the positions of complex positioning systems. Some even use
machine vision. On the actuator side, PLCs drive any kind of electric motor, pneumatic or
hydraulic cylinders or diaphragms, magnetic relays or solenoids. The input/output arrangements
may be built into a simple PLC, or the PLC may have external I/O modules attached to a
proprietary computer network that plugs into the PLC.
PLCs were invented as less expensive replacements for older automated systems that would use
hundreds or thousands of relays and cam timers. Often, a single PLC can be programmed to
replace thousands of relays. Programmable controllers were initially adopted by the automotive
manufacturing industry, where software revision replaced the re-wiring of hard- wired control
panels.
The functionality of the PLC has evolved over the years to include typical relay control,
sophisticated motion control, process control, Distributed Control Systems and complex
networking.
The earliest PLCs expressed all decision making logic in simple ladder logic inspired
from the electrical connection diagrams. The electricians were quite able to trace out circuit
problems with schematic diagrams using ladder logic. This was chosen mainly to reduce the
apprehension of the existing technicians.

1.2 HISTORY:
The PLC was invested in response to the needs of the American automotive
industry. Before the PLC, control, sequencing, and safety interlock logic for
manufacturing automobiles and trucks was accomplished using relays, timers and
dedicated closed-loop controllers. The process for updating such facilities for the yearly
model changeover was very time consuming and expensive, as the relay systems
needed to be rewired by skilled electricians. In 1968 GM Hydromantic (the automatic
transmission division of General Motors) issued a request for proposal for an
electronic replacement for hard-wired relay systems.
The winning proposal came from Bedford Associates of Bedford, Massachusetts.

Tech first PLC, designated the 084 because it was Bedford Associates eighty-fourth
project, was the result. Bedford Associates started a new company dedicated to
developing, manufacturing, selling, and servicing this new product: Modicon, which
stood for Modular Digital Controller. Dick Morley is considered to be the “father” of the
PLC. The Modicon brand was sold in 1977 to Gould Electronics, and later acquired by
German Company AEG and then by Schneider Electric, the current owner.
One of the very first 084 models build is now on display at Modicon’s
headquarters in North Andover, Massachusetts. It was presented to Modicon by GM,
when the unit was retired from nearly twenty years of uninterrupted service.
The first PLC systems evolved from conventional computers in the late 1960’s
and early1970’s these first PLCs were installed primarily in automotive plants.
Traditionally, the auto plants had to be shut down for up to a month at model changeover
time. The early PLCs were used along with other new automation techniques to shorten
the change over time. The PLC keyboard reprogramming procedure replaced the rewiring
of a panel full of wires, relays, times, and other components. The new PLCs helped reduce
change over time to a matter of a few days. With the adventure of the microprocessor
these devices have become very powerful in recent years. Both the personal computers

and PLCs are now used in manufacturing systems. Personal computers and PLC are based
upon microprocessor and these are used for similar type tasks on the shop floor.
Personal computers are generally designed for business used with control a
secondary function and for these personal computers normally it requires additional
interface software and hardware however various stand-alone personal computers are
become available that do have necessary construction to withstand rigors (sense of
coldness with concentration of skin) and demand of the factory environment. This PLCs
are designed for control of equipment of process in an industry environment which
requires high temperature, humidity variation and so on. The PLCs are designed in such
a way that PLC devices are directly connected to machines and industry plant. PLC
doesn’t require a monitor but it has the ability to have several types of peripheral devices
connected to view the status of program that it is running.
1.3 COMPONENTS OF THE PLC:

The basic components of the PLC are as follows:
 Input module
 Output module
 Processor
 Memory
 Power supply
 Programming device

Figure 1.1: Basic elements of PLC.
The input module and output module are the connections to the industrial process
that in to be controlled. The inputs to the controller are signals from limit switches,
pushbuttons, sensors, and other devices. The outputs from the controller in order to operate
motors, valves, and other devices required to actuate the process.
The processor is the central processing unit (CPU) of the programmable controller.
It executes the various logic and sequencing functions. The processor is similar in its
construction to those used in personal computers and microprocessor very other data-
processing equipment. Tied to the CPU is the PLC memory, which contains the program
of logic, sequencing, and other input/output operations.
The memory for a programmable logic controller is specified in the same way as
for a computer, and may range from 1k to over 48 k of storage capacity. A power supply
of 115V ac is specially used to drive the PLC even though the components of the industrial
process that are regulated may have a higher voltage and power rating than the controller
itself.

1.4 BASIC STRUCTURE OF PLC:

The following fig shows the internal structure of PLC. It consists of CPU, memory,
input, and output module. PLC hardware, as in case of almost all of–days microcomputer
systems is based on a bus system. The term bus refers to the path’s or number of electrical
links and it is divided into address such as
1) The Data Bus
2) The Address Bus
The bus is a group of parallel lines. Data bus is an electrical path that connects the
CPU, memory, and other hardware devices on the other board.
Figure 1.2: Architecture of PLC
The Address bus is a set of wires, which is similar to the data bus, but it connects
only the CPU and the memory, and all it carries are memory address. A bus system carries
information and data to from the CPU main memory and input and output module. All the
operations and processes controlled by CPU within the PLC, the software which is the
user program written by PLC user, user programs are usually installed in RAM. A random
memory where they can be easily modified. Control bus or lines are required to activate
the correct bus station either as a transmitter or sender.

1.5 PLC CONNECTIONS:
When a process is controlled by a PLC it uses inputs from sensors to make decisions
and update outputs to drive actuators, as shown in Figure. The process is real process that
will change over time. Actuators will drive the system to new states (or modes of
operation). This means that the sensors available limit the controller, if an input is not
available the controller will have no way to detect a condition.
The control loop is a continuous cycle of the PLC reading inputs, solving the ladder
logic, and then changing the outputs. Like any computer this does not happen instantly.
Figure shows the basic operation cycle of a PLC. When power is turned on initially the
PLC does a quick sanity check to ensure that the hardware is working properly. If there is
a problem the PLC will halt and indicate there is an error. For example, if the PLC backup
battery is low and power was lost, the memory will be corrupt and this will result in a fault.
If the PLC passes the sanity check it will then scan (read) all the inputs. After the inputs
values are stored in memory the ladder logic will be scanned (Solved) using the stored
values – not the current values. This is one to prevent logic problems when inputs change
during the ladder logic scans. When the ladder logic scan is complete the outputs will be
scanned the output values will be changed. After this the system goes back to do a sanity
check, and the loop continues indefinitely. Unlike normal computers, the entire program
will be run every scan. A typical time for each of the stages is in the order of milliseconds.

1.6 INPUT AND OUTPUT:
The input/output unit provides the interface between the system and the outside
world. Programs are entered into the input/output unit from a panel, which can vary from
small keyboards with liquid crystal displays to those using a visual display unit (VDU)
with keyboard. Alternatively the programs can be entered into the system by means of a
link to a personal computer which is loaded with an appropriate software package.
Figure 1.4: The PLC Scan Cycle

The input/output channels provide signal conditioning and isolation functions so
that sensors and actuators can be generally directly connected to them without the need
for other circuitry. Common input voltages are 5V and 24V.
Common output voltages are 24V and 240V. Outputs are specified as being of
relay type, transistor type or Triac type. With the relay type, the signal from the PLC
output is used to operate a relay and so is able to switch currents of the order of few
amperes in an external circuit.

The relay isolates the PLC from the external circuit and can be used for both AC
and DC switching. Relays are relatively slow to operate. The transistor type of output
uses a transistor to switch current through the external circuit. This gives a faster
switching action. The transistor output is only for DC switching. Triac outputs can be
used to control external loads, which are connected to the AC power supply only. Opt
isolators are again used to provide isolation.
1.7 INPUT AND OUTPUT PROCESSING:
Basically ladder programming is used with PLCs. The ladder program consists of
individual rungs containing one output instruction and one or more input instructions. The
rungs could specify the state of switches.
For instance, the switch A and switch B inputs are tested; if switch A and switch B
are both closed then a solenoid, the output is enabled.
1) The following ladder program sequences carried out by means of PLC are:
2) Scan the program inputs with first rung of the ladder diagram.
3) With Ladder program inputs logically solve its operation.
4) Set or rest of the output for rung.
5) Until the end of the ladder program in every sequence it moves on to the next
rung and repeats the operations a, b, c.
When a ladder program is executed, every time each rung of the ladder diagram is
scanned to process the scanning of input/output data. The following two methods are to
be considered.
• Continuous updating
• Mass input or output copying

CONTINUOUS UPDATING:
The operating cycle of a PLC that consists of program scan and input/output scan,
the data associated with external outputs are transferred from the output data file to the
output terminals. Their data is updated during the previous scan of the ladder program and
also the input and output scan where, the inputs are scanned to determine their state and
associated ON/OFF states. During the program scan the updated status of the external
input device are applied to the ladder program. The CPU processes all the instructions in
the ascending rung order in the ladder programs scan that moves from one instruction to
the next instructions through all the rungs of the ladder program.
MASS INPUT OF OUTPUT COPYING:
Whenever updating continuously for each input there should be a delay of 3ms in
time. When we compare for many inputs and output depending upon the length of the
program the time taken will be considerably more. As updating time is much more, to
overcome this and to permit execution of program, temporary memory is used to store the
data and RAM is used as a buffer (Temporary). When each program cycle starts the
microprocessor scans all the inputs with their status and the copies into the I/O addresses
in RAM.
The stored data in RAM are used during every next step which the PLC execute
the program and then stores the result of the execution for subsequent use and at the end
the PLC always updates the status of the outputs.

LADDER LOGIC INPUTS:
PLC inputs are easily represented in ladder logic. In Figure there are three types of
inputs shown. The first two is normally open and normally closed inputs. The III
(immediate Input) function allows inputs to be read after the input scan, while the ladder
logic is being scanned. This allows ladder logic to examine input values more often than
once every cycle.
Figure 1.5: Ladder Logic Inputs
Normally open and active input will close the contact and allow power to flow.
Normally closed, power flows when the input is not open. In ladder logic there are multiple
types of outputs, but these are not cons available on all PLCs. Some of the outputs will be
externally connected to device the PLC, but it is also possible to use internal memory
locations in the PLC. Six outputs are shown in Figure. The first is a normal output, when
energized the will turn on, and energize an output. The circle with a diagonal line through
is an on output. When initially energized the output will turn off. This type of output is not
available all PLC types. When initially energized the OSR (One Shot Relay) instruction
will for one scan, but then be off for all scans after, until it is turned off. The L (latch
unlatch) instructions can be used to lock outputs on. When an L output is energized output
will turn on indefinitely, even when the output coil is de-energized. The only are turned off

using a U output. The last instruction is the IOT (Immediate that will allow outputs to be
updated without having to wait for the ladder logic’s completed.
Figure 1.6: Latch and Unlatch Coils

When power is applied (on) the output x is activated for the left output, but turn off
for the output on the right.
LADDER LOGIC:
PLC had to be maintainable by technicians and electrical personnel. To support

this programming language of Ladder Logic was developed. Ladder Logic is based on
the relay and contact symbols technicians were used to through wiring diagrams of
electrical control panels. Until recently there has been no formal programming standard
for PLC‟s. The introduction of the IEC 61131 Standard in 1998 provides a more formal
approach to coding. PLC Manufacturers have so far been slow on the uptake of the
standard with partial implementation. The Search Eng. article IEC 61131-3, a Standard
for PLC Software by R.W.Lewis provide standard an introduction to the documentation
for early PLC Programs was either non-existent or very poor, just providing simple
addressing or basic comments, making large programs difficult to follow. This has been
greatly improved with the development of PLC Programming Packages.

Figure 1.7: Basic ladder logic concept

Modern control systems still include relays, but these are rarely used for logic. A
relay is a simple device that uses a magnetic field to control a switch, as pictured in
figure when a voltage is applied to the input coil, the resulting current creates a magnetic
field. The magnetic field pulls a metal switch (or reed) towards it and the contacts touch,
closing the switch. The contact that closes when the coil is energized is called normally
open.
The normally closed contacts touch when the input coil is not energized. Relays
are normally drawn in schematic form using a circle to represent the input coil. The
output contacts are shown with two parallel lines. Normally open contacts are shown as
two lines, and will be open (non-conducting) when the input is not energized. Normally
closed contacts are shown with two lines with a diagonal line through them. When the
coil is not energized the normally closed contacts will be closed.
Relays are used to let one power source close a switch for another (often-high
current) power source, while keeping them isolated. An example of a relay in a simple
control application is shown in Figure. In this system the first relay on the left is used as
normally closed, and will allow current to flow until a voltage is applied to the input A.
The second relay is normally open and will not allow current to flow until a voltage is
applied to the input B. If current is flowing through the first two relays then current will
flow through the coil in the third relay, and close the switch for output C. This circuit
would normally be drawn in the ladder logic form. This can be read logically as C will be
ON.

Figure 1.8: Simple Relay
Figure 1.9: Simple Relay Controller
The example in Figure does not show the entire control system, but only the logic.
When we consider a PLC there are inputs, outputs, and the logic. Above figure shows a
more complete representation of the PLC. Here there are two inputs from push buttons.
We can imagine the inputs as activating 24V DC relay coils in the PLC. This in turn drives
an output relay that switches 115V AC that will turn on a light. Note, in actual PLCs inputs

are never relays, but outputs are often relays. The ladder logic in the PLC is actually a
computer program that the user can enter and change. Notice that both of the inputs push
buttons are normally open, but the ladder logic inside the PLC has one normally open
contact.
PROGRAMMING:
Early PLCs, up to the mid-1980s, were programmed using proprietary
programming panels or special-purpose programming terminals, which often had
dedicated function keys representing the various logical elements of PLC programs.
Programs were stored on cassette tape cartridges. Facilities for printing and documentation
were very minimal due to lack of memory capacity. More recently, PLC programs are
typically written in a special application on a personal computer then downloaded by a
direct-connection cable or over a network to the PLC. The very oldest PLCs used non-
volatile Magnetic core memory but now the program is stored in the PLC either in battery-
backed-up RAM or some other non-volatile flash memory.
Early PLCs were designed to be used by electricians who would learn PLC
programming on the job. These PLCs were programmed in “ladder logic”, which strongly
resembles schematic diagram of relay logic. Modern PLCs can be programmed in a variety
of ways, from ladder logic to more traditional programming languages such as BASIC
and C. Another method is State Logic, a Very High Level Programming Language
designed to program PLCs based on State Transition Diagrams.
Recently, the International standard IEC 61131-3 has become popular. IEC 61131-
3 currently defines five programming languages for programmable control systems:
FBD (Function block diagram), LD (Ladder diagram), ST (Structured text, similar to the
Pascal programming language, IL (Instruction list, similar to assembly language) and SFC
(sequential function chart). These techniques emphasize logical organization of operations.

While the fundamental concepts of PLC programming are common to all

manufacturers, differences in I/O addressing, memory organization and instruction set
mean that PLC programs are never perfectly interchangeable between different makers.
Even within the same product line of a single manufacturer, different models may not be
directly compatible.
1.8 REGISTERS TIMER, INTERNAL RELAY AND COUNTERS
Within the PLC CPU registers are found in to location. The microprocessor has
internal Registers most of which are not directly accessible by the user. These registers (4,
8, 16 or 32 bits wide depending on the microprocessor) help the control and arithmetic
and logic units within the processor to carry out their tasks. Accumulator register, data
Registers, index registers condition, code registers, scratch pad registers and instruction
register work to temporarily store data, which in turn is used to facilitate the carrying out
of programmed functions.
In addition to their internal registers, the CPU‟s Rams also contains slots that are
designated to hold variable information. These locations, or address, become external
registers there can be a mere handful of such registers or hundreds depending on the size
of the CPU and complexity of the user program.
Each bit locations in a register contains of course, either 1 or Q O. in addition on

many models you can print on the register contents on a typed keyboard various numbering
system are possible for reading register contents or printing them out. Depending on PLC
capabilities. You may choose to print register valve based on one or more different
numbering systems for E.g.: one model allows you to choose between 1-Decimal 2-Binary
3-Hex, or 4-Ascii other possibilities are actual and special codes unique to the system being
used. Still other PLCs are contained to displaying or printing in only on numbering system
usually decimal systems.

There are functions of five key registers are
1) Holding register
2) Input register (single and group)
3) Output registers (Single and group)
4) Operate to temporarily store data for microprocessor manipulation
PLC TIMER FUNCTIONS:
A single –input timer called a no retentive timer is used in some PLCs. Eg:
Energizing IN001 causes the timer to run for 4 seconds. At the end of 4 seconds the output
goes on. When the input is de-energized the output goes off and the timer resets to 0. If
the input IN001 is turned off during the internal (E.g.: after 2.7 seconds) the timer resets
to 0. In this case the output would not have turned on.
There are disadvantages of the single- input type timer that are overcome by the
multiple input timer. There is 3 type of formats for PLC timers.
1) Block format
2) Coil format with separate enable 4 reset
3) Coil format
The black format includes the enabled reset line. Which allows the timer to run
when energized? When de-energized, the timer is kept at O or reset to 0. The upper line
causes the timer to run when the time is enabled. When enabled the timer runs as long or
the run input is energized. If Two other timer functions are including in some PLCs. Time
delay on 4-time delay off there are 3 states in a timing cycle.
1) The initial or reset state

2) The state during timing 4
3) The state after timing is complete

Figure 1.10: TON Timer Logic diagram
A system of “X‟ for on 4 „0‟ for off is normally used. The examples illustrate this
convention. In some system as 1 is used instead of an x to indicate contract closed.
EXAMPLES OF TIMER FUNCTION INDUSTRIAL APPLICATION
Some commonly used timer functions are
1) On delay output B comes on at a specific set time after output A is turned on. When
A is turned off B also goes off.
2) Off delay. Both A and B have been turned on at the sometime. Both are in
operation. When A is turned off, B remains on for a specific set time period before
going off.
3) Limited on time A and B go on at the same time B goes off after specific set time
period but A remains on.
4) Repeat cycling, An output pulses on and quickly off at a constant pre-set time into
5) On-shot operation, output B goes on for a specified time after output A is turned
on. Output B will run for its specified time interval even if A is turned off during
the B timing interval.

6) Alternate on 4 off two outputs. An E.g. of this timing. Application is two alternately
flashing signal lights. The time on for each of the two lights may be the same or
the two times could be set to different intervals.
7) Multiple on delay 2 different event start at different time intervals after an initial
starting time reference point. Multiple off delay 2 different functions remain on for
two different time intervals after a process is turned off.
8) Interval time within a cycle e we may require that an output come on 7.5 seconds.
After system start up remain on for 4 seconds and then go off 4 stay off. The
interval would then be repeated only after the system is shut off and then turned
back on.
PLC COUNTER
A counter is a PLC instruction that either increments (counts up) or decrements

(counts down) an integer number value when prompted by the transition of a bit from 0
to 1 (“false” to “true”).
Counter instructions come in three basic types:
1) up counters
2) down counters
3) Up/down counters
Both “up” and “down” counter instructions have single inputs for triggering
counts, whereas “up/down” counters have two trigger inputs: one to make the counter
increment and one to make the counter decrement.
PLC Counter Instructions

To illustrate the use of a counter instruction, we will analyze a PLC-based system
designed to count objects as they pass down a conveyor belt:

Figure 1.11: PLC Counter Illustration
In this system, a continuous (unbroken) light beam causes the light sensor to close
its output contact, energizing discrete channel IN4. When an object on the conveyor belt
interrupts the light beam from source to sensor, the sensor’s contact opens, interrupting
power to input IN4.A push-button switch connected to activate discrete input IN5 when
pressed will serve as a manual “reset” of the count value. An indicator lamp connected to
one of the discrete output channels will serve as an in indicator of when the object count
value has exceeded some pre-set limit. We will now analyze a simple Ladder Diagram
program designed to increment a counter instruction each time the light beam breaks.

Figure 1.12: PLC Counter in ladder logic
This particular counter instruction (CTU)is an incrementing counter which, means

it counts "up" with each off-to on transition input to its "CU" input. The normally-closed
virtual contact (IN sensor object) is typically held in the "open" state when the light beam
is continuous, by virtue of the fact the sensor holds that discrete input channel energized
while the beam is continuous. When the beam I broken by a passing object on the conveyor
belt, the input channel de-energizes, causing the virtual contact IN sensor object to "dose"
and send virtual power to the "CU" input of the counter instruction. This increments the
counter just as the leading edge of the object breaks the beam. The second input of the
counter instruction box ("R") is the reset input, receiving virtual power from the contact IN
switch reset whenever the reset pushbutton pressed. If this input is activated, the counter
immediately resets its current value (CV) to zero.

1.9 MANUFACTURING AND ASSEMBLY PROCESS
PLC‟s is used to automate manufacturing and assembly process. By “process”, we

mean step-by-step procedure where by a product is manufactured and assembled. It is the
responsibility of the Product Engineering (PE) department to plan for the manufacture of
new or modified products. According to Rehg and Kraebber, in their book. manufacturing,
2nd ed., the plan has seven elements.
1) Process planning.
2) Production machine programming.
3) Tool and fixture Engineering.
4) Work and production standard
5) Process planning.
6) Production machine programming.
7) Tool and fixture Engineering.
1.10 MERITS AND DEMERITS OF PLCS
Merits:
1) Flexibility: - In the past, each different electronically controlled production machine

required its own controller, 15 machines might require 15 different controllers. Now
it is possible to use just one model of a PLC to run any one of the 15 machines.
Furthermore, you would probably need fewer than 15 controllers, because one PLC
can easily run many machines.
2) Lower Cost: - Increased technology makes it possible to condense more functions into
smaller and less expensive packages. Now you can purchase a PLC with numerous
relays, times, and controllers, a sequencer, and other functions for under a hundred
dollars.

3) Visual Observation: - In advanced PLC systems, an operator message can be

programmed for Control of Traffic Signal Lights by Using PLC reach possible
malfunction. The malfunction description appears on the screen when the malfunction
is detected by the PLC logic.
4) Speed of Operation: - Relays can take an unacceptable amount of time to actuate. The
operational speed for the PLC program is very fast. The speed for the PLC logic
operation is determined by scan time, which is a matter of milliseconds
5) Ladder or Boolean Programming Method: - The PLC programming can be

accomplished in the ladder mode by an electrician or technician. Alternatively, a PLC
programmer who works in digital or Boolean control systems can also easily perform
PLC programming.
6) Reliability and Maintainability: - Solid-state devices are more reliable, in general, than
mechanical systems or relays and timers. The PLC is made of solid-state components
with very high reliability rates. Consequently, the control system maintenance costs
are low and down time are minimal.
7) Ease of changes by Reprogramming: - Since the PLC can be reprogrammed quickly,

mixed production processing can be accomplished.
8) Security: - A PLC program change cannot be made unless the PLC is properly
unlocked and programmed. Relay panels tend to undergo undocumented changes.
People on late shifts do not always record panel alterations made when the office area
is locked up for the night.

Demerits
1) Newer Technology: - It is difficult to change the thinking of some personnel from

ladders and relays to the PLC computer concept.
2) Fixed Program Applications: - Some applications are single function application. It
does not pay to use a PLC that includes multiple programming capabilities if they
are not needed.
3) Environmental Considerations: - Certain process environments, such as high heat
and vibration, interfere with the electronic devices in PLCs, which limit their use.
4) Fail-safe Operation: - In relay systems, the stop button electrically di connects the
circuit if the power fails, the system stops. Furthermore, the relay system does not
automatically restart when power is restored.
5) 5 Fixed Circuit Operation: - If the circuit in operation is never altered, a fixed
control system might be less costly than a PLC. The PLC is most effective when
periodic changes in operation are made.

CHAPTER 2
DESIGN AND IMPLEMENTATION OF PLC TRAINER

WORKSTATIONS

2.1 STRUCTURE OF PLC TRAINER WORKSTATION

PLC workstations are fabricated using 40x40 aluminum profile. Five PLC
workstations are made in one frame. Each workstation is consisting of independent PLC
and computer having separate power connections. Acrylic panels designed and fabricated
using laser engraving and cutting machines to accommodate power supply switches, push
buttons, PLC, output indicators etc. Allen-Bradley Micro 820 PLCs are used. Connected
Components Workbench (CCW) version 13 software is used for designing and downing
the ladder program for PLC
2.2 ALUMINUM FRAME

Seven 4040 aluminum profile of each 6m length is used for fabrication of frame.
Each workstation is having width of 4 feet to ensure the comfortable accommodation for
PLC, computer and other power supply unit and input-output components. Frame initially
designed using “Item online CAD”, which helps in designing and preparing the components
requirement for fabrication of frame. L-cl frame. MPs, rubber vacuum feet, 8mm T-nuts
and screws are used for the F
Figure 2.1: PLC Trainer Work Station

Panel Board drawing is prepared using Solid Edge software as shown in figure
2.2. Red lines in the figure shows the slot cutting areas and blue lines are for engraving.
At most care is taken accommodate all the mountings on the panel board for
easy accessibility and understanding. Then the CAD drawings DXF format is sent for
cutting and engraving on the 5mm thick acrylic sheet.
Figure 2.2: Solid Edge Drawing for Acrylic Panel Board

Figure 2.3: Acrylic Panel Board prepared using Laser engraver and cutter
Figure 2.3 shows finished acrylic panel sheet. From the sketch it clear seen that all
the interfacing and mounting provisions are made in the panel board
2.3. PROGRAMMABLE LOGIC CONTROLLER (PLC)
Each work station has Allen-Bradley Micro 820 PLC. Totally five PLC are used in
this project. The AB PLC model having catalogue number 2080-LC20-20QBB is used here.
This Micro820 series PLC has 20 point (12 IOs) Micro PLC is specifically designed for
small standalone machines and remote automation projects with embedded Ethernet and
serial ports. It has a Controller, 12 24V DC Inputs, 4 configurable analogue input with
thermistor voltage reference out, 7 24V DC Source Output, 1 Analog Output, Embedded
Ethernet Port and RS- 232/485 non-isolated Serial port, Embedded RTC, Micro-SD Card
support, 2 Plug-In slots.

Figure 2.4: Allen-Bradley Micro 820 PLC
It can function as a RTU (remote terminal unit) for remote machines with support
for Modbus RTU and TCP. It has embedded support for 4 thermistor temperature inputs
for use as a DDC (direct digital controller) for Building Management Systems.
The Micro820 supports an embedded micro-SD slot that can be used for storing
large amounts of data that normally cannot fit into memory for applications that require
data log and recipe. All files are stored in CSV text format for easy viewing and editing.
The micro-SD card is also used for backing up and restoring the program, which can be
used for duplicating the program in several machines.

2.4. PLC PROGRAMMING SOFTWARE
Connected Components Workbench software (CCW) is developed by Rockwell
Automation. CCW Version 13 is used in this project. This software has following
features
• Easy to configure – Single software package reduces initial machine development time
and cost
• Easy to program – Simplify programming process with sample code and user-defined
function blocks
• Easy to visualize – Reference Micro800 controller variables directly when creating
HMI tags Connected Components Workbench design and configuration software
offers controller programming, device configuration, and integration with HMI editor.
Figure 2.5: CCW version 13 Software

2.5 POWER SUPPLY
Each work station has independent power supply. 24 volts 5 amps DC power
Supply is used is shown in fig 2.6. Two separate DPST switches are used for PLC and
other components of the workstation.
Figure 2.6: 24 Volts 5 amps DC SMPS

CHAPTER 3
FABRICATION OF THE TRAFFIC LIGHT SIGNAL MODEL

INTRODUCTION
Traffic signals control vehicle and pedestrian traffic by assigning priorities to

various traffic movements to influence traffic flow. Properly designed, located and
maintained traffic signals have one or more of these advantages:
• Provide for orderly movement of traffic;

• Increase traffic-handling capacity of an intersection;
• Reduce frequency and severity of certain types of crashes, especially right-angle
collisions;
• Provide for continuous movement of traffic at a definite speed along a given route;
• Interrupt heavy traffic at intervals to permit other vehicles or pedestrians to cross.
Traffic signals are not a solution for all traffic problems at intersections, and
unwarranted signals can adversely affect the safety and efficiency of traffic by causing
one or more of the following:
• Excessive delay;
• Increased traffic congestion, air pollution and fuel consumption;
• Disobedience of signals;
• Increased use of less-adequate streets to avoid traffic signals;
• Increased frequency of crashes, especially rear-end collisions.
Traffic signals are designed to ensure an orderly flow of traffic, provide an

opportunity for pedestrians or vehicles to cross an intersection and help reduce the number
of conflicts between vehicles entering intersections from different directions. Following are
indications of traffic light.

Red A red signal means “STOP”.

Yellow A yellow signal light means “CAUTION”, the red signal is about to
appear.
Green A green light means “GO”.
3.2 Structure of Traffic Light signal model
Figure 8.1: Traffic Interaction Point

The main aim in designing and developing of the Traffic Signal is to reduce the
waiting time of each lane of the cars and also to maximize the total number of cars that can
cross an intersection. The Intelligent Traffic Signal Control System consists of two
important parts. The first part is the PLC controller and second part is hardware. These
usually comprise of red, yellow, and green lights.

Logic Description:
Two-way traffic interaction is considered for designing the traffic light for the given
location. When the START push button is pressed sequence shown in Table 8.1 takes place.
When START button is not pressed or the STOP button is pressed the yellow light on both
direction (SOUTH and EAST) will flash continuously until the START button is ON.
Table 3. 1 Traffic Light sequence in East and south Directions.
Components required
Sl No Component Specification Quantity

name
1 POWER SUPPLY
2 PLC 1
3 INDICATORS 6
4 ALUMINIUM
FRAME
5 BANANA PINS 8
FEMALE

ALUMINIUM FRAME:
BANANA PINS FEMALE:

INDICATORS :
Ladder diagram:
Rung 1 Diagram: Start the main switch of traffic signal by pressing START button and
switch off by using STOP button

Rung 2 Diagram: To run timer for YELLOW 1
Rung 3 Diagram: To turn on YELLOW 1 and turn it OFF
Rung 4 Diagram: To turn on GREEN 1 timer after YELLOW 1light turns OFF

Rung 5 Diagram: To turn on GREEN 1 light and turn it OFF
Rung 6 Diagram: To run YELLOW 2 timer after the GREEN 1 timer
Rung 7 Diagram: To turn on YELLOW 2 and turn it OFF

Rung 8 Diagram: To run the timer for GREEN 2 after YELLOW 2 timer
Rung 9 Diagram: To turn on GREEN 1 and turn it OFF
Rung 10 Diagram: To turn on RED 1 after GREEN 1 turn OFF

Rung 11 Diagram: To turn on RED 2 along with YELLOW 1 and turn it off with GREEN 1
Result: A Two way traffic signal light is designed and tested successfully.

CHAPTER 4
ESTIMATION AND COSTING

EASTIMATION AND COASTING
On Estimating this project, we get the idea of the cost of the project and hence its
feasibility can determinate i.e., whether the project could be taken up within the funds
available or not. Estimation gives an idea of time required for the completion of the work.
costing its provides a tool for price fixations as well as price control costing can be
help the make decisions about tariff protection, and it can also offer information relating to
wage. A final advantage of costing is that it helps us within to make decisions about wages.

ESTIMATION AND COSTING TABLE:
Sl No
Particulars Quantity Rate Amount
1 4040 Aluminum Profile 48 meters 430 20640

2 2020 Aluminum Profile 6 meters 160 960
3 2040 Aluminum profile 6 meters 300 1800
4 Slot filling Beading 60 meters 18 1080
5 L clamps 70 28 1960
6 T-Nuts & Bolts 140 12 1680
7 Aluminum Fixture for 2020 & 2040 and others 3168
8 Leveling Pad 10 100 1000
9 Transportation(Aluminum Profiles) VRL 3840
10 Acrylic Panel-5mm thick 5 2200 11000
11 Power Supply 24 Volt, 5 amps 5 650 3250
12 PLC –Micro 820 5 11500 57500
13 Banana Pins Female 250 8 2000
14 3mm LED with Holder 250 2 500
15 Proximity Sensors 250 10 2500
16 Molex 24 Pin Connectors 250 10 2500
17 Terminal Connector 20 10 200
18 DPST switches 10 20 200
19 Digital Voltmeter & Ammeter 5 250 1250
20 Indicators 20 50 1000
21 DC Motor 1 200 200
22 ACP sheet 8x4 1 85/sq ft 2720
140 /sq Ft
23 WPVC Sheet 8X4 1 4480
Miscellaneous 5000
Grand Tot Rs. 1,30,428

Chapter 5
CONCLUSION

CONCLUSIONS
This PLC Trainer kit is an experimental platform, by using this ladder logics
programs can be checked. This equipment is specially built for teaching and student
community. Following are the some of the important from the project work.
1. Helps in understanding the PLC interfacing

2. Helps in understanding the Lift/Elevator programming.
3. Kit is modular and can be connected to any application.
4. Ladder programming helps to develop complex logic programs with ease.
5. Wherever needed sensors can be used instead of limit switch.
conclusions drawn

REFERENCE
1. Programmable logic Controllers By W. BOLTON

2. Digital electronics By FLYOD
3. Exploring PLC with applications By PRADEEP KUMAR SRIVATSAVA
4. Automation, Production systems and Computer Integrated Manufacturing By
MIKELL
5. GROOVER
6. Sensors Hand book-SABRIE SOLOMAN-MC-GRAW HILL publications
7. Hand book of Modern Sensors” Physics, Designs and Applications- JACOB
FRADEN- Springer Publications
8. Electric Motors and Drives BY AUSTIN HUGHES and BILL DRURY

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Controlling of Traffic signal light using PLC 2022-23

DME SJEP Govt. Polytechnic Bangalore - 560001 1

We are grateful to Smt, GAYATHRI V Principal, and Sri, HARISH KUMAR S V,

We thank staff member of Government Polytechnic, Holenarasipura for extending their

DME SJEP Govt. Polytechnic Bangalore - 560001 2

Chapter 1: Introduction to Programmable Logic Controller Page No

Chapter 2: Design and Implementation of a PLC Trainer Workstation 28-34

Chapter 3: Fabrication of traffic light signal model 35-44

Chapter 4: Estimation and Costing 45-47

DME SJEP Govt. Polytechnic Bangalore - 560001 3

DME SJEP Govt. Polytechnic Bangalore - 560001 4

DME SJEP Govt. Polytechnic Bangalore - 560001 5

The winning proposal came from Bedford Associates of Bedford, Massachusetts.

DME SJEP Govt. Polytechnic Bangalore - 560001 6

1.3 COMPONENTS OF THE PLC:

DME SJEP Govt. Polytechnic Bangalore - 560001 7

Figure 1.1: Basic elements of PLC.

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1.4 BASIC STRUCTURE OF PLC:

1) The Data Bus

2) The Address Bus

Figure 1.2: Architecture of PLC

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1.5 PLC CONNECTIONS:

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1.6 INPUT AND OUTPUT:

Figure 1.4: The PLC Scan Cycle

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1.7 INPUT AND OUTPUT PROCESSING:

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MASS INPUT OF OUTPUT COPYING:

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LADDER LOGIC INPUTS:

Figure 1.5: Ladder Logic Inputs

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Figure 1.6: Latch and Unlatch Coils

PLC had to be maintainable by technicians and electrical personnel. To support

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Figure 1.7: Basic ladder logic concept

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Figure 1.8: Simple Relay

Figure 1.9: Simple Relay Controller

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While the fundamental concepts of PLC programming are common to all

1.8 REGISTERS TIMER, INTERNAL RELAY AND COUNTERS

Each bit locations in a register contains of course, either 1 or Q O. in addition on

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There are functions of five key registers are

2) Input register (single and group)

3) Output registers (Single and group)

4) Operate to temporarily store data for microprocessor manipulation

PLC TIMER FUNCTIONS:

1) The initial or reset state

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Figure 1.10: TON Timer Logic diagram

EXAMPLES OF TIMER FUNCTION INDUSTRIAL APPLICATION

Some commonly used timer functions are

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A counter is a PLC instruction that either increments (counts up) or decrements

PLC Counter Instructions

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