EAT237 Microprocessors and PLCs

Coursework Assignment (PLC-Part)

This coursework exercise will provide you with the opportunity to demonstrate the skills you
will develop throughout the module. Specifically, the following learning outcomes will be
assessed:

• Design and implement a program using flow charts to solve a range of problems.
• Design and specify measurement and sensor systems to interface with microprocessor
and PLC based applications.
These learning outcomes will be assessed through the year through as you work through a
mini project where you will complete various activities.
Scenario

You have been contracted to develop the control system for tyres recycling system. The system has
multiple stages of operation to recycle a complete tyre. The system consists of the following stages.

1- The system receives the tyres on a conveyor belt which delivers the tyres to a shredder.
2- A conveyor belt that moves the shredded tyres towardsa a steel separating machine.
3- a conveyor belt moves the shredded elements towards a magent that extracts the metal
from the lot.
4- The metal free rubber then moves towards a second shredder that cuts the rubber into
smaller size parts.
5- A coveyor belt then moves the rubber towards a vibrating screen that drops same size
rubber into a hopper.
6- When hopper is full a pneumatic cylinder extends to tie the bag and the entire system stops
until an operator change the bag and press the start button again.
7- The remaining rubber moves towards a granulating machines that fines down the rubber
into poweder. The output of the granulator is moved on a conveyor belts towards a hopper
for bagging.
8- When a bag is full, its conveyor belt stops and a pneumatic restrictor emerges to block the
flow of rubber poweder.

The system has a start and stop buttons. The system has emergency stop button placed after
the second shredder as well.
 The system has an HMI screen that present the state of each conveyor and shredder. In
addition the screen presents how many parts are produced each hopper, ie. Vibrating screen
hopper and the three poweder hoppers.

Requirements

PLC Design Notes (30 marks)

You will produce a set of design notes for the PLC program based on the required functionality
described above. This may include:

• Flowchart or Sequential Function Chart

• I/O list
• Variable list
• Comments on the purpose of each rung
• Electrical Drawings
• Pneumatic drawings
• HMI program.
PLC Program (20 marks)
You are required to include your PLC and HMI program. You will have the opportunity to
demonstrate the functionality of your program. You can use either the provided PLC and HMI
or you can use the simulator.

During the programming session you will work individually and will be provided with access
to the following documentation:

• CCW programming manual

• Micro820 hardware manual
• CCW quick start guide

You may not collaborate or communicate with anyone else and you may not bring any other
material (including any electronic copies of code etc on memory sticks) into the session other
than the design notes which will be submitted at the end of the session. You will have 60
minutes to complete the coding.

Engagement with Lab Sessions

While there are a number of elements to this assessment much of the work is based on the
activities that you will carry out during the laboratory sessions. Therefore, if you engage with
these activities you will greatly enhance your chances of achieving a good mark. After each
session you should try to think about how the material covered could contribute to the
assignment and make a note of this to support the design exercise.

The laboratory sessions will involve the use of the Rockwell Micro 820 PLC. Any submission
for alternative devices e.g. Arduino, Siemens PLCs etc. will not be accepted.

Importance of Design
One of the most important themes in this module is design. It is critical, therefore, that you
allow adequate time to design your program. If you fail to do so you will not only jeopardise
the design elements of the coursework but you will also make it extremely difficult to score
well for the coding activities.

Avoiding Accusations of Plagiarism

Any code you write must be entirely your own. You may bring listings into the coding sessions
but if these have been sourced from another source e.g. a text book or the internet, then this
must be fully acknowledged using comments which clearly and unambiguously identify the
extent of the code involved (e.g. by labelling the start and end of the section in question) and
the source. You should also ensure that all work in the written submissions is your own and
correctly referenced. Where you draw on references you should ensure that you clearly
explain their relevance to your own work. If you are unsure on the correct way to reference
any material, please ask or refer to the guidance available via the University Library Website:
http://library.sunderland.ac.uk/find-resources/referencing/

Presentation of Work
Presentation of work is of critical importance. The elements being submitted electronically
should be typed and clearly formatted making appropriate use of headings and subheadings.
Your design notes for the PLC program may be hand written or typed but MUST be clear and
legible.
 Marking Scheme

PLC Design Notes (30%)

Design notes which should include:

• a flowchart or Sequential Function Chart, /5
• I/O and variable list /10
/10
• electrical drawings
/5
• Pneumatic drawings

PLC and HMI Program (20%)

/10
Demonstration of required functionality:

/10
Structure of PLC program:
• Appropriate use of instruction blocks
• Clear logical structure
• Use of sensible/appropriate variable and alias names
• Clear and appropriate use of comments

N.B. Written elements will be assessed using the University of Sunderland Generic Assessment
Criteria https://docushare.sunderland.ac.uk/docushare/dsweb/Get/Document-7861/AQH-F6-
15%20Generic%20Assessment%20Criteria.pdf