systems can also be automated. The main advantage of automation in manufacturing are high quality and consistency, reduction in the lead times, to simplify.
International Journal of Emerging Technology in Computer Science & Electronics (IJETCSE) ISSN: 0976-1353 Volume 21 Issue 3 – APRIL 2016.
MODEL BASED APPROACH IN THE IMPLEMENTATION OF INDUSTRIAL AUTOMATION USING PLC Amal Allet Seema M #1, Pandiammal K*2 # ME Applied Electronics, ECE Dept., Jerusalem College of Engineering, Chennai-600 100, Tamil Nadu, India. *Assistant professor, ME Applied Electronics, ECE Dept., Jerusalem College of Engineering, Chennai-600 100, Tamil Nadu, India. Automated factories and processes are too expensive to re built the whole system for every design change and modification – so they have to be configured easily and they are flexible. To reconfigure an entire production line successfully or process requires direct access to most of its control elements – switches, valves, motors and drives – down to a detailed level. PLC related applications are more complex when more components are involved. If some error occurs, diagnosing them can take some time, but a logical procedure will reduce the time needed to locate the fault. The probability that a failure will occur in different parts of typical PLC systems shows that almost 95% of PLC system faults are external and occur on plant items such as sensors, actuators, transducers, limit switches and others. The possibility of determining the validity of the data gathered from all transducers of the control system helps in a way of short time fault detection. Consequently, a fault-tolerant control system must be implemented using redundancy in the logic of PLC programming.
Abstract— Industrial applications in the present scenario demand the design of safe, more complex, and trustworthy control systems exhibiting a high degree of reutilization and flexibility. To achieve this, the engineering process has to be improved by making the engineering tools involved in the development process to collaborate during the design. This project presents a model-based approach for designing coolers in automation applications. The core of the approach is to improve the performance of coolers in automation industry. Alarm auto reset and redundancy in Ladder Logic are implemented to increase the cooler performance. Programmable Logic Controllers are integrated (PLC) along with the Supervisory Control and Data Acquisition (SCADA) systems to control the operation of a cooling process in an industry. To send only the critical signals to central control system (CCS) and control the other alarms locally. The Local control panel (LCP) is equipped with a SCADA which acts as a communication interface between PLC and Operator. The SCADA’s touch screen makes it possible for the Operator to monitor various functions, change parameters and display actual values. Index terms—Automation, Central Control System (CCS), direct communication, Local Control Panel (LCP), Programmable Logic Controllers (PLC), Supervisory Control and Data Acquisition (SCADA)
II.RELATED WORK The Object oriented programming is used to improve the relationship between structure and behavior [1].The PLC is based on IEC 61131-3.The 3SCodesys v3 software is used to bring about the execution of model based approach. Three well known and widely used industrial standards have been used: Computer Aided Engineering eXchange (CAEX), PLCopen (a representation format for the IEC 61131-3 standard) and MathML (a language for defining mathematical constraints). Using model checking it is possible to assure the correctness of the control system specification and using model transformation it is possible to detect design errors in early stages of the design. Integrating these three standards was a major drawback.[2] Four Software design methodologies well suited for flexible manufacturing process was analyzed[3]. Step-based ladder logic proved to be simple and 80% more
I.INTRODUCTION Automation is the big part of our vision of future technology. In the scope of industrialization, automation is just a step beyond mechanization. Whereas mechanization provided human operators along with the required machines to assist them with the muscular efforts of work, automation greatly reduces the need for human mental and sensory requirements as well. Processes and systems can also be automated. The main advantage of automation in manufacturing are high quality and consistency, reduction in the lead times, to simplify production, improve work flow, reduce handling and support the efforts of the workers when a good implementation of the automation is made.
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International Journal of Emerging Technology in Computer Science & Electronics (IJETCSE) ISSN: 0976-1353 Volume 21 Issue 3 – APRIL 2016. time saving. This Project uses step based ladder logic programming for its analysis. III.METHODOLOGY In the present industry the communication between the equipment’s and the central control system is direct. This has led to the following problems. -Inter equipment communication does not exist. -If there is a failure in any one of the equipment’s, then all equipment’s will be affected. -Error comparison and optimization iteration is not possible. To overcome these issues, communication is established between the LCP and the CCS. The equipment’s are connected to the LCP and monitored.
Fig.1 Block Diagram of cement manufacturing process. The Process of the cooler is analyzed in this project. It cools the clinker from the kiln (Since it is 1200◦C -1400◦C), so it can be transported to storage or grinding departments. It provides secondary air to aid the kiln burner function and also provides hot air to aid the material preheating processes. Coolers can provide additional hot air to dry raw materials. The hot clinker, from the clinker output is cooled in the cooler by means of cooling fans and the circulation of air is established by means of mechanical flow regulators.
A. Communication between CCS and LCP. The communication between CCS and LCP is being established using Profibus DP. This is the performance optimized version of Profibus, specifically dedicated to time critical communication between automation systems and distributed peripherals. It is suitable as a replacement for the costly parallel wiring of 24 VDC and 4-20mA measurement signals. Profibus DP is included in the European Field bus Standard EN 50170.Profi Bus DP is an Open standard based on EN 50170.It is the fastest Field bus standard to date with data rates up to 12MB.It uses Plug & play operation. Up to 244 bytes of input/output data per message can be transmitted. It is possible to connect up to 126 stations to the bus. Each bus can connect up to 32 stations per bus segment.
D. Function of the cooler system Each module contains a hydraulically driven cylinder. The movable frames of each module are attached to the next module’s movable frame essentially creating one large frame per module wide drive.The closed circuit hydraulic drive system strokes the movable frames back and forth at a determined speed.The stationary cross-bars create a dam during the back stroke reducing the chance a back flow of clinker.The control of underground grate flow is established by means of mechanical flow regulators.
B. The purpose of the LCP is to -Control operation of single machine. -Process and display various measuring points -Perform test and adjustment during commissioning -Alarm abnormal conditions -Communicate with CCS. -Inter machine communication is better achieved. -Man less operation.
The diagram of mechanicel flow regulators is shown below:
RESISTANCE
C. Process analyzed Given below is the typical block diagram of cement manufacturing process.
Fig.2
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Mechanical Flow regulators
International Journal of Emerging Technology in Computer Science & Electronics (IJETCSE) ISSN: 0976-1353 Volume 21 Issue 3 – APRIL 2016. E. Abbreviations and Acronyms PLC Programmable Logic Controller SCADA Supervisory Control and data acquisition MDE Model Driven Engineering UML Unified Modeling Language SysML Systems Modeling language CAEX Computer Aided Engg EXchange LCP Local Control Panel CCS Central Control System RS Reverse stop FS Forward stop RAS Reverse auto stop FAS Forward auto stop PID Proportional Integral Derivative Fig.4
F. Oil conditioning unit of the cooler It has a closed – loop temperature control to maintain the temp between 22◦c to 52◦c.The heating valve will be operated, when the temp is < 22◦c. The cooling valve will be on when the temp is > 52◦c and it will be off when the temp is 60◦C, a warning will be generated. If the tank oil temp is > 65◦C, a tripping alarm will be generated and the system will be tripped.
Fig.3
Process Interlock diagram of cooler
H. Cooler Hydraulics The movement of a drive is controlled by a piston oil pump, which is able to deliver oil flow in two directions. The oil flows from port A resulting in forward movement of the drive cylinders or from port B resulting in reverse movement of the drive cylinders. The oil flow amount and the oil flow direction are controlled by an electrically controlled proportional servo oil valve. A shuttle valve located by the side of the cylinder drains a part of the oil from the main oil circuit to the oil tank, at the beginning of each cylinder movement. A servo oil pump, mounted on the same shaft of the main pump, supplies oil to the pilot system. Further, it takes care of refilling the main pump circuit with the oil drained by the shuttle valve. I. Cooler system The purpose of the Cooler control system is to control the drive moment with a stroke speed according to the speed set point received from CCS and to ensure that selected stroke length is maintained. The stroke of the drive is max. 150mm (25 to 175mm).To maintain the selected stroke length under varying clinker load, four stop limits are defined. The stroke length is the distance between RS and FS. The two limits are adjustable for each drive from a parameter picture on the control display .RAS and FAS are limits, which are controlled by two PID controllers to initiate stop ramps in time to reach RS and FS.The ramps are introduced to make the acceleration and deacceleration smooth.
Flow diagram of the oil conditioning pump
G. Process flow sheet of the cooler The figure shown shows the process flow diagram of a cooler.
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International Journal of Emerging Technology in Computer Science & Electronics (IJETCSE) ISSN: 0976-1353 Volume 21 Issue 3 – APRIL 2016. The figure shown below shows the forward auto stop and reverses auto stop movement of the drive.
Fig.5
Drive movement
J. Drives control The drives control facilitates selection between three different transport patterns.
Fig.7
overview of organization block
The interconnection between these blocks is shown in the figure below:
The figure show below shows the different modes of operation.
Fig.6
Different modes of Drive operation.
Random Mode: (transport- and reverse strokes are individually controlled for each drive; separate speed set-point for each drive).
Fig.8
interconnection between various blocks
A. Program Execution • Create a new project in Simatic tool of Siemens
Shuttle Mode: (synchronized transport strokes and two step reverse strokes; - at first the central drive and when in reversed position the outer drives; one speed set-point for all drives);
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Hardware configuration
Synchro Mode: (Synchronized transport strokes and synchronized reverse strokes; onespeed set-point for all drives).
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Creation of organisation block(OB)
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Creation of functions and function blocks(FB)
IV.BLOCKS USED IN PROGRAMMING
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After each creation of FB, call them in OB.
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Databases are created for assigning temporary data values.
1) Organisation block 2) Functions 3) Function blocks
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International Journal of Emerging Technology in Computer Science & Electronics (IJETCSE) ISSN: 0976-1353 Volume 21 Issue 3 – APRIL 2016. B. AUTO ALARM RESET SYSTEM HEALTHY: The parameters to be considered for auto alarm reset are shown in figure.
Fig.11 Fig.9
parameters for auto alarm reset
Analog simulation values
VI.CONCLUSION AND FUTURE WORK In this project we have analyzed the advantages of LCP near the Equipment. LCP model has been created to establish inter equipment communication. If the communication with the CCS fails or there is a system server problem with the CCS, the LCP can take over the whole Control and enable smooth execution. Thereby the efficiency of the plant production is maintained. The auto alarm reset and the PLC ladder logic redundancy has been implemented. Communication between different PLC in the CCS and LCP will also be analyzed and implemented in the future.
V.SIMULATION RESULTS The screenshot below shows the digital simulation values of the auto alarm reset program.
REFERENCE
Fig.10
1)V. Vyatkin, ―Software engineering in industrial automation State-of-the art review,‖ IEEE Trans. Ind. informat.,vol.9,no.3, pp. 1234–1249,Aug. 2013. 2) V. Hajarnavis and K. Young, ―An assessment of PLCsoftware structure suitability for the support of flexible manufacturing processes,‖ IEEE Trans. Autom. Sci. Eng., vol. 5, no. 4, pp. 641– 650, Oct. 2008. 3)F. Basile, P. Chiacchio, and D. Gerbasio, ―On the implementation of industrial automation systems based on PLC,‖ IEEE Trans. Autom. Sci.Eng., vol. 10, no. 4, pp. 990–1003, Oct. 2013. 4)E. Estevez and M. Marcos, ―Model-based validation of industrial control systems,‖ IEEE Trans. Ind. Informat., vol. 8, no. 2, pp. 302–310, May 2012 [5] N. Papakonstantinou and S. Sierla, ―Generating an object oriented IEC 61131-3 software product line architecture from SysML,‖ in Proc. IEEE 18th Conf. Emerg. Technol. Fact. Autom. (ETFA), Cagliari, Italy, 2013,pp. 1–8. [6] N. Papakonstantinou, S. Sierla, and K. Koskinen, ―Object oriented extensionsof IEC 61131-3 as an enabling technology of software productlines,‖ in Proc. 16th IEEE Conf. Emerg. Technol. Fact. Autom. (ETFA),Toulouse, France, 2011, pp. 1–8. [7] D. Witsch and B. Vogel-Heuser, ―PLC-statecharts: An approach to integrateUML-statecharts in open-loop control engineering—Aspects onbehavioral semantics and modelchecking,‖ in Proc. 18th IFAC WorldCongr., Milano, Italy, 2011, vol. 18, pp. 7866–7872.
Digital simulation values
Analog scaling for temperature input- simulation result. The screen shot shown below shows the analog input simulation values for the oil temperature alarm reset.
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International Journal of Emerging Technology in Computer Science & Electronics (IJETCSE) ISSN: 0976-1353 Volume 21 Issue 3 – APRIL 2016. [8] D. Witsch, ―Modellgetriebene Entwicklung von Steuerungssoftwareauf Basis der UML unter Ber¨ucksichtigung der dom¨anenspezifischenAnforderungen des Maschinen- und Anlagenbaus,‖ Ph.D. dissertation,Technische Universit¨at M¨unchen, Lehrstuhl f¨ur Automatisierung undInformationssysteme, M¨unchen, Germany, 2013. [9] European Committee for Standardization, ―Ergonomic requirements for office work with visual display terminals (VDTs)—Part 11: Guidance on usability (ISO 9241-11: 1998),‖ Beuth Verlag GmbH, 1998. [10] B. Vogel-Heuser et al., ―Evaluation of a UML-based versus an IEC61131-3-based software engineering approach for teaching PLC programming,‖IEEE Trans. Edu., vol. 56, no. 3, pp. 329–335, Aug. 2013
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