ELECTROTECHNICS LABORATORY Nro: 3.

Lab 3 - Practices Topic: Forklift with alarm

WORKSHEET: P4B .

Forklift with alarm

Objetive:

This project aims to improve the control system of an elevator by incorporating new functionalities and safety alarms.
Audible and visual alarms will be added, one if the cabin door remains open for more than a minute and another if the
call button is pressed with the door open from another floor. Additionally, thermal motor failure will be incorporated, and
the alarm can be reset if the appropriate key is pressed. Signaling the location of the elevator and detecting problems in
the system are important measures to ensure safety and efficiency. These measures allow for quick identification and
problem resolution, reduce maintenance costs, and improve elevator performance. It is expected that these
improvements will increase the safety and efficiency of the elevator, providing a better experience for users.

Development of the practice:

To the previous system, incorporate an audible alarm if the cabin door remains open for more than 1 minute (1-second
cadence every 10 seconds). The alarm will be reset when the door is closed. Another alarm with a flashing signal of 4
pulses (0.5-second cadence) if the call is pressed from/to a floor with the door open. The alarm will only sound when the
call is pressed, then it will not repeat. The idea is to alert the user that there is an error when requesting the elevator.
Incorporate thermal motor failure with input I8. The thermal protection device should have automatic reset, and the
alarm condition is memorized using an RS flip-flop, displayed on the screen along with the date and time of the event.
The alarm can be reset if the thermal device is normal and also by pressing the • + Esc key on the PLC for 3 seconds.
When the thermal alarm condition exists, the elevator cannot move. The PLC display should indicate which floor the
elevator is on at all times.

*Diagram and scheme of the system, as well as any graphic representation that helps to understand the proposed test.

Img. Nro 1 Initial Wiring Electrical Diagram. Img. Nro 2 Simulation Model.

Name María Eugenia Szwedowski Group:3ero ID3 Date: 05/04/2023 Page 1

ELECTROTECHNICS LABORATORY Nro: 3.1

Lab 3 - Practices Topic: Forklift with alarm

Img.

Ladder diagram - Img Nro 3 Block diagram - Img. Nro 4

Img. Nro 5 Ladder Alarma Relé Inactivo NA.

Name María Eugenia Szwedowski Group:3ero ID3 Date: 05/04/2023 P ag e 2

ELECTROTECHNICS LABORATORY Nro: 3.1

Lab 3 - Practices Topic: Forklift with alarm

Control Electrical Circuit- Img Nro 6 Power Electrical Circuit - Img. Nro 7

The Phase-Time Diagram- Img. Nro 8

Name María Eugenia Szwedowski Group:3ero ID3 Date: 05/04/2023 P ag e 3

ELECTROTECHNICS LABORATORY Nro: 3.1

Lab 3 - Practices Topic: Forklift with alarm

Calculations and justifications for the sizing of elements.

In the design and programming of a forklift control system, it is necessary to perform adequate calculations and
dimensioning to ensure proper operation of its components. These components may be mechanical, electrical, or
electronic.

Firstly, it is necessary to perform calculations to size the mechanical elements of the forklift, such as the cabin load
capacity, diameter and strength of the lifting cables, motor power and speed, among others. These calculations are
performed based on the forklift's characteristics, such as maximum load weight and required height.

On the other hand, it is necessary to perform electrical calculations to size the control system elements, such as the up
and down contactors, call buttons, and limit switches. For sizing the contactors, it is necessary to know the nominal
current of the lifting motor and the system's supply voltage. It is important to consider a safety margin in the nominal
current, as the motor may experience current spikes during startup. Call buttons and limit switches are sized based on
the maximum current and voltage they must withstand.

In PLC programming, the forklift's operation sequence must be considered, that is, how the elements are activated and
deactivated based on the system inputs. In the described forklift, when a plant's call button is activated, the
corresponding contactor must be activated for the lifting motor to raise or lower the cabin. Additionally, it is necessary to
consider the state of the limit switches and the closed cabin door to prevent undesired forklift movements.

Explanation of how each part is executed: assembly, tests, measurements, etc.

To execute the previously described forklift project, it is necessary to follow an orderly and systematic process that
ensures the system operates safely and efficiently. This section will describe each part of the process in detail, from
assembly to testing and measurements.

► Assembly. The assembly of the forklift's electrical system is carried out following the electrical diagram and
manufacturer specifications. It is important to ensure that components are installed correctly and connected securely.
Electrical safety standards should be followed during assembly to ensure system integrity and prevent accidents.

► Programming. The programming of the PLC is a critical part of the assembly process. The program must take into
account the system's inputs and outputs and the logic required to make real-time decisions. The programmer should
ensure that the program is easy to read and maintain.

► Testing. After assembly and programming, tests are carried out on the system to verify that it functions as expected.
These tests include verifying the correct connection of electrical components, measuring electrical signals, testing the
inputs and outputs of the PLC, and checking the operation of safety functions. It is important to keep a record of test
results to make adjustments and improvements to the system.

► Measurements. Once initial tests have been performed, additional measurements are taken to ensure the safety and
efficiency of the system. This includes measuring the current and voltage in electrical lines, measuring component
temperatures, and checking for proper synchronization of cabin movements. Measurements should be taken according
to electrical safety standards.

Name María Eugenia Szwedowski Group:3ero ID3 Date: 05/04/2023 P ag e 4

ELECTROTECHNICS LABORATORY Nro: 3.1

Lab 3 - Practices Topic: Forklift with alarm

Record

Datasheets and/or characteristics of the elements used.

♦ INPUTS
►I1: 1st floor call button (T). NC. Activated = 1; Deactivated = 0
►I2: 2nd floor call button (1). NC. Activated = 1; Deactivated = 0
►I3: 3rd floor call button (2). NC. Activated = 1; Deactivated = 0
►I4: 1st floor limit switch. NC. Activated = 1; Deactivated = 0
►I5: 2nd floor limit switch. NC. Activated = 1; Deactivated = 0
►I6: 3rd floor limit switch. NC. Activated = 1; Deactivated = 0
►I7: Cabin door closed. NC. Activated = 1; Deactivated = 0
►I8: Thermal relay. NO. Activated = 0; Deactivated = 1

►I9: Reset button for Relay. NC. Activated = 1; Deactivated = 0

♦ OUTPUTS
►Q1: Up contactor output. Activated = 1; Deactivated = 0
►Q2: Down contactor output. Activated = 1; Deactivated = 0
►Q3: Alarm output. Activated = 1; Deactivated = 0

I1 I2 I3 I4 I5 I6 I7 I8
Q2 = 1 0 0 0 1 0 1 1
Q2 = 1 0 0 0 0 1 1 1
Q1 = 0 1 0 1 0 0 1 1
Q2 = 0 1 0 0 0 1 1 1
Q1 = 0 0 1 1 0 0 1 1
Q1 = 0 0 1 0 1 0 1 1

Name María Eugenia Szwedowski Group:3ero ID3 Date: 05/04/2023 P ag e 5

ELECTROTECHNICS LABORATORY Nro: 3.1

Lab 3 - Practices Topic: Forklift with alarm

Conclusions and Observations

The practice carried out on the three-level freight elevator, using PLC programming, has allowed for important
conclusions to be drawn regarding the proper functioning of the system. First, it has been demonstrated that the correct
installation and assembly of the input and output sensors and devices is fundamental to the proper functioning of the
system.

Recently, improvements have been made to the system, including signals indicating the elevator's location in case the
door has been left open. Additionally, it has been found that programming is a dynamic process that requires constant
review and improvement to ensure proper functioning.

Signaling to the user the location of the elevator is an important safety and efficiency measure in the design of elevator
systems. This signaling allows the user to know which floor the elevator is on and facilitates the selection of the
corresponding call button. Furthermore, this signaling can include additional information, such as the direction of
elevator movement or whether the door is open or closed.

On the other hand, identifying motor malfunctions with the relay failure is an important safety measure to avoid potential
accidents. If a problem is detected in the motor, the relay is responsible for interrupting the electrical supply and
stopping the entire system, thereby preventing possible risks to the user.

In addition, having the ability to quickly identify and solve problems in the motor and other system components can
significantly improve elevator efficiency and performance. This results in less downtime and greater system availability
for users.

Another benefit of signaling and problem detection in the system is the reduction of maintenance costs. By quickly
identifying problems, measures can be taken to solve them before they become costly repairs. Additionally, appropriate
signaling can reduce the possibility of system damage due to incorrect use by users.

The practice has also allowed for an understanding of the importance of safety in the design and configuration of
electrical systems, leading to the implementation of various safety measures, such as detection of a closed door and
protection against thermal overload, ensuring safe operation and preventing possible accidents.

Furthermore, it has been highlighted that PLC programming is a very versatile tool that allows for great flexibility in the
configuration of electrical and electronic systems, adapting to different needs and requirements, making it a very useful
tool in the automation of industrial processes. The practice has allowed for an understanding of the importance of these
aspects and how their proper implementation can ensure safe and efficient system operation.

Name María Eugenia Szwedowski Group:3ero ID3 Date: 05/04/2023 P ag e 6