Acknowledgments

It gives us great pleasure to thank all those who assisted us for completion of the project.

First of all we would like to thank our beloved Head of Department
Engr. Dr. HAROON RASHEED for his valuable suggestions and support without which the project
would have been in-complete.

We are very thankful to our supervisor Engr. MASOOD USMAN for helping us thoroughly during the
course of the project.

Finally we express our deep gratitude to the staff of the department of Electrical/Electronic Engineering
for their kind co-operation in assisting us in our project.











Abstract
The task is to make a system in which we can measure and control the feed of the two different solid
(crushed form) materials according to the desired ratio. Measuring the temperature and the level of solid
material present in the hopper (storage area) before it is sent to the further process. Since we are making
industrial based project so it has to be accurate in the desired functions with less error losses.
We have completed our projects work. We have chosen the DELTA PLC EX2 for our project with an
extension module of digital IOs. Compatible HMI will be used for the display of sensor values and text.
Main features of the project are as under:

To sense & feed the different proportion of different raw materials to the any plant.
Also using HMI to set the proportion of feed.
Load sensors which sense the weight of the raw material in the main hoper.
Temperature will be measured before the material moves on under the uncertain conditions feed will
be stopped.


Table of contents
DESCRIPTION PAGE #
A List of Symbols And Units
1 Introduction
1.1 Objective
1.2 Project Overview
1.3 Block Diagram
1.4 Scope Of The Project
1-3
1
1
2
3
2 Background And Literature Review
2.1 Introduction To PLC
2.2 History Of PLC
2.3 Manufacturers Of PLC
2.3.1 Specification Of PLC (DVP 20-EX2)
2.4 PLC Vs Computers
2.4.1 Environmental Factor
2.4.2 Easy Learning
2.4.3 Simple Execution of Programs
2.4.4 Expandability
2.4.5 Development Time & Application Level VS Cost
4-11
4
4-5
5
6
7-9
7
7
8
8
9
3 Aims and Statement of Problem
3.1 Scope Of The Project
3.2 Amendments In the Project
3.3 Problems Due To Academic Side
3.4 Role of Administration
3.5 Problems Statement
Selection Of Valve
Troubleshooting Of PLC
Problem With IR Circuit
Problem With Amplifier
HMI & PLC Communication
10-16
10
10
11
11
11
11-13
13
14-15
16
16
4 Analysis And Design
4.1 Analysis Of Existing System
4.1.1 Problems In The Existing System
4.2 Proposed System
4.3 Advantages Of The Proposed System
4.4 Working Of The Proposed Design
4.5 Detailed Design
4.5.1 Software
4.5.2 Hardware
4.6 Instrumentation Signals
17-23
17
17
18
19
20
21
21
22
23
5 Hardware Implementation
5.1 Sensors (LOAD,LM35)
5.2 IR Transmitter And Receiver
5.3 Amplifier Circuit
5.4 DC Gear Motor
5.5 Designing Of The Valve
5.5.1 Motor Rev/Fwd Wiring
5.5.2 Research Paper Done For The Valve
5.5.3 Finalized Best Suited And Economical Design
5.5.3.1 Advantages Of The Designed Valve
5.6 Research Work Done For The Project
24-33
24-26
27
28
29
30
30
31-32
32
32
33
6 Programmable logic Controller (PLC)
6.1 About PLC
6.2 Leading Vendors Of the PLC
6.3 Advantages Of The PLC
6.4 PLC I/O Point Wiring
6.5 Delta Vs Siemens PLC
6.6 Output Configuration
6.7 Ladder Logic Of PLC
34-47
34
35
35-36
37-38
38
39
40-47
7 Human Interface Machine (HMI)
7.1 About HMI
7.2 Advantages Of HMI
7.3 RS-232 Protocol
7.3.1 RS-232 Pin Definitions
48-52
48
49
50
50
7.4 HMI Screens 51-52
8 Testing Of The Complete System 53
9 Results 54
10 Conclusions 55
11 References 56
12 Appendix: A 57





List of Symbols &Tables

UNITS SYMBOLS

Centigrade C
Millimeter mm
Kilohertz KHz
Megahertz MHz
Ohms
Second sec
Farad F
Revolution per minute rpm
Watts W
Ampere A
Voltage V

Table 1: History OF PLC
Table 2: Specifications Of PLC
Table 3: Specs Of Load Cell
Table 4: Delta VS Siemens





PLC BASED AUTOMATIC FEED SYSTEM VIA HMI

vii

List of Figures
Figure 1: Main Block Diagram Of The Project.
Figure 2: Delta PLC With Digital Module
Figure 3: Cost VS Environment
Figure 4: Cost VS Expandability
Figure 5: Development Time VS Application Level
Figure 6: Plunger Valve
Figure 7: Butterfly Valve
Figure 8: Our own valve design
Figure 9: IR OLD CKT
Figure 10: IR NEW CKT
Figure 11: Real world Design of PCB
Figure 4: Problem With Amplifier
Figure 5: Design Of Proposed System
Figure 6: PLC Ladder Logic Software
Figure 7: HMI Screen Software
Figure 8: Main Hopper System
Figure 9: Control Panel and Conveyor Belt
Figure 10: LM 35
Figure 11: IR TX & RX
Figure 12: Amplifier ckt
Figure 13: DC Gear Motor
Figure 14: Projects Valve design
Figure 23: Motor Rev/Fwd Wiring
Figure 24: Needle Gate Valve
Figure 25: PLC I/O wiring
Figure 26: PLC o/p wiring
Figure 27:Digital module o/p wiring
Figure 28:RS-232 Pin Configuration