Benha Faculty of Engineering

Benha University
Mechanical Department

Process Control Project

Presented to:
Dr. Nader Abdelwahab

Made by:
1. Mazen Yasser Farid
2. Ali Khaled Ali
3. MohamedPresented
Ibrahim Atta
to:
4. Shehab
Dr. El-Den Saber
Nader Abdelwahab
5. Mohamed Yasser Mohammed
6. Mahmoud Ashraf Abd El-Fattah
7. Mostafa Ashraf Goda
Contents
1. PLC. .................................................................................................................. 3
2. HMI .................................................................................................................. 6
2.1. Siemens Automation ................................................................................. 6
2.2. Omron Automation ................................................................................... 7
3. Photo from Project. ......................................................................................... 9
4. TIA Portal ....................................................................................................... 11
5. Factory IO ...................................................................................................... 13
6. Real time implementation ............................................................................... 14
7. Logix Pro. ....................................................................................................... 15
8. Connection .................................................................................................... 17
9. Components. ................................................................................................. 18
10. SolidWorks Design. ..................................................................................... 20
11. Hardware. ................................................................................................... 21
 1. PLC.

Sub-system Description

CPU  Signal processing function

-. Operating system function

-. Application program storage / memory function

-. Data storage / memory function

-. Application program execution function

Input  The input signals obtained from the machine/process to appropriate signal levels for
processing

Output  The output signals obtained from the signal processing function to appropriate
signal levels to drive actuators and/or displays

Power Supply  Provides for conversion and isolation of the PLC system power from the main supply

Communication  Provides the data exchange with other systems or PADT, such as KGLWIN, personal
Interface computers
K7M-DRT/DT30U

I/O Point & Power 18 DC inputs(24VDC)

Supply
8/0 relay outputs

4/12 TR outputs

85~264 VAC

Built-in Function • Program capacity: 10 k steps

• Max. expansion: 3 modules
• High-speed counter:
- 1 Phase: 100 kHz 1channel, 20 kHz 2channel.
- 2 Phase: 50 kHz 1channel, 10 kHz 1channel.

• Pulse catch: pulse width 10 ㎲- 2 points, 50 ㎲- 6 points,

• External interrupt: 10 ㎲- 2 points, 50 ㎲- 6 points

• Input filter: 0 ~ 1000ms (can be designated with groups)

• PID control function

• RS-232C communication, RS-485 communication

• Positioning function

- 2axes 100 kpps

- Absolute / Incremental positioning method
- Single / Repeat operation method
- End / Keep / Continuous mode
- Return to origin, JOG, PWM, velocity control
Power Supply / CPU

K7M – DR/DRT/DT30U
Rated voltage 85 ~ 264 VAC
Input Rated frequency 50 / 60 Hz (47 ~ 63 Hz)
Rated current 0.5A(110VAC)/0.25A(220VAC)
Inrush current Up to 30A
Output(1) Output voltage DC 5V
Output current 1.2A
Output(2) Output voltage DC 24V
Output current 0.2A
 2. HMI
Human Machine Interface, often known by the acronym HMI, refers to a dashboard or screen
used to control machinery. Line operators, managers and supervisors in industry rely on HMIs to
translate complex data into useful information.
For example, they use HMIs to monitor machinery to make sure it’s working properly. Easy-to-
understand visual displays give meaning and context to near real-time information about tank
levels, pressure and vibration measurements, motor and valve status and other variables.
But the advanced capabilities of today’s HMIs enable managers and supervisors to do much more
than control processes. Using historical and trending data they offer vast new opportunities to
improve product quality and make systems more efficient.
For all these reasons, HMIs play a key role in the smooth and effective running of factories and
manufacturing operations.
In our project we used Two HMI

2.1. Siemens Automation

Siemens was used to provide our project with Simulation By using RT Simulator

Figuer1.2- RT Simulator
 2.2. Omron Automation
Omron Automation is an industrial automation leader that creates, sells and services fully
integrated automation solutions that include Robotics, Sensing, Motion, Logic, Safety, and more.
Established in 1933 and currently headed by President Yoshihito Yamada, Omron’s 36,000
employees help businesses solve problems with creativity in more than 110 countries [1].They focus
on issues rooted in manufacturing sites and production lines, developing an extensive lineup of
control products and control applications to solve these issues. These products and applications
harness cutting-edge technologies like AI, IoT, and robotics, and are brushed up for usability
before release.

Figuer1.1- Developing control products and control applications for solving "10 m or less" manufacturing
issues.

We used NB7W-TW10B from Omron NB-series.

The Omron NB-series HMIs are designed for use in industrial automation and control systems.
They provide a user-friendly interface for operators to monitor and control machinery and
processes. Some common features of Omron NB-series HMIs include:
1- Touchscreen Interface: The NB-series typically features a touchscreen interface for
easy navigation and operation.
2- Graphics and Visualization: These HMIs often support high-quality graphics for
displaying process information, alarms, and other data.
3- Communication Protocols: Omron HMIs are designed to communicate with various
PLCs (Programmable Logic Controllers) and other automation devices, supporting
protocols such as Ethernet/IP, Modbus, and more.
4- Programming Software: Omron provides programming software for developing
applications on their HMIs. This software allows users to design screens, set up
communication, and program logic for the HMI.
5- Compact and Durable Design: The hardware is typically designed to withstand
industrial environments, with features such as compact form factors, durable
construction, and resistance to environmental factors like dust and moisture.
 Installation onto the Operation Panel
 Functions of NB-Designer

3. Photo from Project.

4. TIA Portal
5. Factory IO

The design on the Factory IO

When filling the tank

 When emptying the tank

6. Real time implementation

There are three modes:

 Mode1: The tank continues to fill until it reaches the upper level, at which
point the sensor (High level sensor) detects and then opens the outlet valve
until the tank is empty, then the cycle repeats.
 Mode2: The tank continues to fill until it reaches the upper level, at
which point the sensor senses and opens the outlet valve until the tank is
empty, then waits 30 seconds, then the cycle repeats.
 Mode3: The tank continues to fill until a specified time which corresponds
to a certain limit of the tank volume, without relying on a high level sensor,
then the outlet valve opens until the tank is empty, then the cycle repeats.

Emergency: If there is a leakage in the tank, the sensor detects this leakage and
sounds an alarm.
7. Logix Pro.
8. Connection

Circuit similar to the hardware board

 9. Components.
Components Num Description Picture

LS PLC K7M-DRT30U
PLC 1 Siemens S7 1200
CPU1214c

DC Motor 2 DC 12V 80W 13000rpm

RI 60J DC
LS Rated current: 0.5 -
1
Contactor 63 A Rated short
capacity: 4.5 kA

ANU AD60-22DS-240V-
Led 4 Indicator Light

40*30 cm Plastic Box

Box Panel 1 panel

Sound Buzzer - 5 Volt

Buzzer 1
Cable duct 6 2X2In Server Rack Cable

Momentary Push Button-

Bush Potton 3 AC 660V 10A

Electric selector switch -

Ø22 - standard handle - 3
Selector 1 positions - 2NO

Wooden
1 82*62 cm Wooden board
Board
10. SolidWorks Design.
11. Hardware.