TECHNOLOGICS GLOBAL PRIVATE LIMITED

Industrial Automation
Project
Course: Post-Graduate Diploma in Automation & Control

Prepared and submitted by: ARNAB CHOUDHURY (TECHINBLR/2017/02/001930)

Under supervision of: Mr. SANTOSH KUMAR (Application Engineer)
CONTENTS

1. Acknowledgment

2. Introduction

3. Programmable Logic Controller

4. Visualization

5. PLC selection

6. Software for Programming

7. Project Description

8. Programming

9. Conclusion

10. Resources
ACKNOWLEDGEMENT

This is to express my gratitude towards Technologics Global Private Limited for creating such
comprehensive course on the basic and advanced applications of Automation and Control.
The course achieves its goal of providing a strong foundation in the basics of automation for
both beginners and experienced individuals through diligent efforts of the trainers at
Technologics, Mr. Sudhir, Mr. Saifi, Ms. Reshma and Mr. Santosh. The course provides
exposure to design, configuration, programming, installation, commission and
troubleshooting of the popular products from leading brands of PLC, DCS, HMI, VFD and
SCADA.
This industrial project has been prepared under the supervision of Mr. Santosh Kumar and is
being submitted to meet the requirements of course completion.
Working on this project has been insightful as it relates to real-world application of PLCs in
Industrial Automation.

- Arnab Choudhury
April 13, 2018
INTRODUCTION
In recent years, the scope of automation
has rapidly expanded in both industrial and
non-industrial applications. Advances in
automation technology, reduced cost of
requisite hardware/software, improved
process efficiency, delocalization of
industries, demand for increased
productivity due to competition, stricter
safety norms etc. have stimulated the
acceptance of automation benefits in the
social and corporate realms alike.
Automation has been traditionally defined
as “the technique of making an apparatus,
a process, or a system operate
automatically.” In the modern context, The
International Society of Automation (ISA)
– a non-profit organisation setting
The global automation market is expected
to grow at 6% annual growth rate (CAGR)
to $149 billion by 2022. As India is catching
up with the first world countries in
automation with a projected annual growth
of 12% during 2015-2020. Growth in the
market is anticipated in automotive,
chemicals, and other manufacturing units,
along with various government initiatives
aimed at increasing domestic
manufacturing. Automation can be
categorized in various segments:
By type:
standards in the field of automation,
defines automation “the creation and
application of technology to monitor and
control the production and delivery of
products and services.” Adoption of this
modern definition reflects on the
importance of automation products and
services for industrial applications.
Automation is no longer in its nascent
experimental phase. It offers significant
financial and strategic benefits to convince
even the most traditional institutions to
transform its time tested operating models
to incorporate automation in a bid to stay
relevant as we transition from the 3rd
industrial revolution to the 4th which is also
known as “Industry 4.0”
 Fixed automation
 Programmable automation
By end-user:
 Machine manufacturing
 Oil & gas
 Aerospace & defence
 Electrical & electronics
 Automotive & transportation
 Chemical
 Pharmaceuticals
 Mining & metals
 Food & beverages
 Power generation
By technology:
The scope of this project is limited to
Programmable Logic Controllers (PLC),
Human Machine Interfacing/Visualization
(HMI).
PROGRAMMABLE LOGIC CONTROLLER (PLC)
PLCs are a family of programmable process
controllers which does not have any
moving contacts by way of using solid state
devices such as transistors, triacs and
thyristors. It generates specific outputs
Over the next few sections, a brief
introduction of PLC, HMI and SCADA has
been presented before narrowing down on
the assigned project.
intended to control process based on user
defined parameters and sequential
programming. Below is the commonly
referenced PLC architecture.
Types of PLC
Based on Power supply: Based on Output type: Based on Design:

 With SMPS  Relay type  Fixed type PLC

 Without SMPS  Transistor type  Modular type PLC
 Triac type  Rack type PLC

PLCs are specifically intended-for and or machine vision systems. PLC output can
therefore tolerant-of more severe include elements such as indicator lamps,
conditions (such as dust, moisture, heat, sirens, electric motors, pneumatic or
cold), while offering extensive hydraulic cylinders, magnetic relays,
input/output (I/O) to connect the PLC to solenoids, or analog outputs. The
sensors and actuators. PLC input can input/output arrangements may be built
include simple digital elements such as into a simple PLC, or the PLC may have
push-buttons, limit switches, analog external I/O modules attached to a fieldbus
variables from process sensors (such as or computer network that plugs into the
temperature and pressure), and more PLC. Further details shall be presented in
complex data such as that from positioning the next section “PLC SELECTION”.
VISUALIZATION
Visualization is necessary for the Human involving variable value based changes to
Machine Interface which is the Graphical color, fill, orientation, movement, size etc.
User Interface for the PLC at the field level. provides an easier way to give inputs,
Visual elements such switches, lamps, observe process conditions and check
sliders, shapes etc. with varied features output.
PLC SELECTION
Below is a comparison of the PLC/Software available at Technologics laboratory which could
be suitable for this project:

Micrologix 1400
ML-50 Masterlogics

Allen-Bradley
TM218LDA24DRN

SIMATIC S7-300
AC500 PM554-T
CP1E-E2-0DRA

Honeywell
Schneider
DVPSP2811R

Siemens
Keyence

Omron
KV24DR

Delta

ABB

Type Modular, Modular, Fixed, Modular, Modular, Modular, Modular- Modular,

w/o Slim type, w/ SMPS, w/ SMPS, w/o w/o Rack type, w/o
SMPS, w/o Relay type Relay type SMPS, SMPS, w/o SMPS,
Relay type SMPS, Transistor SMPS,
Relay type type

I/Os 24 DIO 28 DIO 20 DIO 24 DIO 14 DIO 32 DIO 40 DIO 32 DIO,

availability/

Total 6 AIO 6 AIO

Onboard

I/P 16 DI 16 DI 12 DI 14 DI 8 DI 16 DI 24 DI 20 DI
I/O

4 AI 4 AI
O/P 8 DO 12 DO 8 DO 10 DO 6 DO 16 DO 16 DI 12 DO
2 AO 2AO
Op. 0 - 50°C 0 - 55°C 0 - 55°C 0 - 55°C 0 - 60°C 0 - 55°C 0 - 60°C -20 -
Ruggedness

Temp 60°C

Op. 35-85% 50-90% 10-90% 95% 95% 95% 5-95% 5-95%

Humid max max max
 Prog. 2,000 15,872 2,000 1 Mb 128 kb 10,000 128 kb 2,000
Memory
/steps (10 kb)

Data 3,000 10,000 2,000 5,120 5,000 8 Mb 5,120

/words (10 kB) (MMC) (10 kb)

Scan 140 µs 1.4 µs 0.4 µs 2 ms 0.08-1.2 0.16 µs 0.07- 0.7 ms

Through µs 0.72 µs Through
Response

-put Through Through -put

time

Executi 1.19-3.12 0.24 µs 1.19-7.4 -put -put

on µs µs

Interface opt./ RS232 RS232, RS232 RS232, RS-485 RS232 Profibus, RS232,
RS485:
Communication RS485 RS485, RS485 DF1,
RJ45: DH485,
Serial, Modbus,
Modbus, DNP3,
ASCII,
TCP/IP Ethernet
Prog. Language LD, IL LD, IL, LD LD, IL, LD, IL, LD, IL LD, IL, LD, SFC,
SFC SFC, SFC, SFC, FBD, ST
FBD, ST, FBD, ST, FBD, ST,
CFC CFC GRAPH

Cost ~$139 ~$230 ~$285 ~$130 ~$335 ~$460 ~$1,700 ~$385

Expansion 80 DIO 512 DIO Not 152 DIO 256 DIO 480 DIO 256 DIO 256 DIO
max max possible 64 AIO max max
max

After-sales Obsolete Obsolete Available Available Obsolete Available Available Available

(unconfir
med)

Based on the requirements of the project and initial I/O mapping, Schneider
TM218LDA40DRN has been selected – for the following reasons:
1. Cheaper than other prominent brands
2. Comes with 24 DIs and 16 Dos which suffices the project requirement
3. Programming software SoMachine is based on CoDeSys which is available for project
4. Reputed brand and good after-sales service

SOFTWARE FOR PROGRAMMING

CoDeSys v3.5 SP12 (3S-Smart Software
Solutions) has been selected for the
programming requirements. Schneider’s
official programming package SoMachine
is based on CoDeSys.
Program prepared in CoDeSys can be
implemented in Schneider’s SoMachine
with necessary addressing changes.
CoDeSys is an intuitive programming
platform which is fully IEC61131-3
compliant i.e. it supports all six
programming languages namely ladder
logic (LD), instruction list (IL), function
block diagram (FBD), sequential function
chart (SFC), continuous function chart
(CFC) and structured text (ST). This
software also provides for easy
visualization options which have been used
for this project.
Over 250 device manufacturers from
different industrial sectors offer intelligent
automation devices with a CoDeSys
programming interface. Consequently,
thousands of end users such as machine or
PROJECT DESCRIPTION
The project describes a sorting-by-size
process at a factory where the operation
has 3 modes: Auto, Manual & Sampling.
The system comprises a conveyor belt
system, overhead mobile claw/grabber
unit, size-specific storage bins, sensor
arrays and control motors.
Auto Mode requires a repeatable
automated operation without manual
control. The conveyor motor starts when
PS1 sensors detects any product placed on
the conveyor. The conveyer carries the
product through 3 sensors, PS2, PS3 and
PS4, arranged according to the height of
the product variety i.e. A, B and C.
Detection by these 3 sensors segregate
products based on their size. If PS2 triggers
plant builders around the world employ
CoDeSys for all sorts of automation tasks.
This software is distributed with free
license by 3S-Smart Software Solutions
making it a preferred choice of learners and
hobbyists for programming.
alone – Product A; if PS2 & PS3 triggers –
Product B; if PS2, PS3 and PS5 triggers –
Product C.
Sensor PS5 placed at the end of the
conveyor path detects the product to stop
the conveyor motor. This initiates the
grabber operation.
The grabber moves in 2 mutually direction
- x axis and y axis, to pick up the product
from the conveyor and then to drop it into
a specific storage bin. Sensors PS6 and PS8
detect whether the grabber is in its origin
position while idling. PS5 initiates the
grabber to move in x-direction toward
conveyer, to halt and pick up the product
when sensor PS7 detects the grabber and to
return to its original position re-triggering
 PS6 and PS8. The grabber then moves in y-
direction to drop off the product at its
assigned storage. To ensure proper drop-
off, PS9, PS10, PS11 and PS12 have been
arranged over the storage bins. Combing
on the selection logic of sensors PS2, PS3
and PS4 with PS9, PS10, PS11 and PS12, the
appropriate storage bin receives the
intended product.
Sample Mode has been proposed for
sampling and has to be selected at the start
of Auto Mode operation. Using Sample
push button, any of the 3 products,
irrespective of its size, to be delivered to a
designated storage bin for samples marked
by sensor PS12. The sample can then be
retrieved for quality assurance or any other
purpose it may serve.
Manual mode is provided for the
eventuality of a system malfunction
involving any of the components used in
automating the process. It could be used
during maintenance, calibration and
process reset after events like power
failure, device failure or accidents. In this
mode, the operator has complete control
over the operation of the conveyor and the
grabber. Sensors, limits and interlocks do
not feature in this mode. 7 separate
switches are provided at console for the
manual operation.

PROGRAMMING
The program has been written in Ladder a. Auto
Diagram. The program is split into 4 b. Manual
components namely: 3. Function blocks
a. Grabber pick operation
1. Main Program
b. Grabber drop operation
2. Sub-routines
4. Visualization
I/O Mapping:

Global Local Name Type Address POU Pg Type Var Type

Yes Start BOOL %IX0.0 PLC_PRG PRG VAR
Yes Stop BOOL %IX0.1 PLC_PRG PRG VAR
Yes Sel_Auto BOOL %IX0.2 PLC_PRG PRG VAR
Yes Sel_Manual BOOL %IX0.3 PLC_PRG PRG VAR
Yes PS1 BOOL %IX0.4 POU_AUTO PRG VAR
Yes PS5 BOOL %IX0.5 POU_AUTO PRG VAR
Yes PS5 BOOL %IX1.1 POU_AUTO PRG VAR
Yes PS6 BOOL %IX1.2 POU_AUTO PRG VAR
Yes PS7 BOOL %IX1.3 POU_AUTO PRG VAR
Yes PS8 BOOL %IX1.4 POU_AUTO PRG VAR
Yes PS9 BOOL %IX1.5 POU_AUTO PRG VAR
Yes PS10 BOOL %IX1.6 POU_AUTO PRG VAR
Yes PS11 BOOL %IX1.7 POU_AUTO PRG VAR
Yes PS12 BOOL %IX2.0 POU_AUTO PRG VAR
Yes Sample BOOL %IX2.1 POU_AUTO PRG VAR
Yes RI BOOL %MX0.0 PLC_PRG PRG VAR
Yes Grabber_Pick BOOL %MX0.4 POU_Grab_Pick FB VAR
Yes Grabber_Drop BOOL %MX0.6 POU_Grab_Drop FB VAR
Yes M10 BOOL %MX1.0 POU_AUTO PRG VAR
Yes Conv_Mtr BOOL %QX0.0 POU_AUTO PRG VAR
Yes Mtr1_FWD BOOL %QX0.1 POU_AUTO PRG VAR
Yes Mtr1_REV BOOL %QX0.2 POU_AUTO PRG VAR
Yes Mtr2_FWD BOOL %QX0.3 POU_AUTO PRG VAR
Yes Mtr2_REV BOOL %QX0.4 POU_AUTO PRG VAR
Yes PS2 BOOL %IX0.6 POU_AUTO PRG VAR
Yes PS3 BOOL %IX0.7 POU_AUTO PRG VAR
Yes PS4 BOOL %IX1.0 POU_AUTO PRG VAR

Yes Conv BOOL %IX2.2 POU_MANUAL PRG VAR

Yes Mtr1_F BOOL %IX2.3 POU_MANUAL PRG VAR
Yes Mtr1_R BOOL %IX2.4 POU_MANUAL PRG VAR
Yes Mtr2_F BOOL %IX2.5 POU_MANUAL PRG VAR
Yes Mtr2_R BOOL %IX2.6 POU_MANUAL PRG VAR
Yes Grab_S_Pick BOOL %IX2.7 POU_MANUAL PRG VAR
Yes Grab_S_Drop BOOL %IX3.0 POU_MANUAL PRG VAR
Yes Prdt_A BOOL %MX0.1 POU_AUTO PRG VAR
Yes Prdt_B BOOL %MX0.2 POU_AUTO PRG VAR
Yes Prdt_C BOOL %MX0.3 POU_AUTO PRG VAR
Yes M0 BOOL %MX0.5 POU_Grab_Pick, POU_MANUAL FB VAR
Yes M3 BOOL %MX0.7 POU_Grab_Drop, POU_MANUAL FB VAR
Yes M20 BOOL %MX1.1 POU_AUTO PRG VAR
Yes M21 BOOL %MX1.2 POU_AUTO PRG VAR
Yes M22 BOOL %MX1.3 POU_AUTO PRG VAR
Yes Start_Pick BOOL POU_Grab_Pick FB VAR_INPUT
Yes TON_0 TON POU_Grab_Pick FB VAR
Yes M1 POU_Grab_Pick FB VAR_OUTPUT
Yes M2 TIME POU_Grab_Pick FB VAR
Yes R_Trig_0 RTRIG POU_Grab_Pick FB VAR
Yes Stop_Pick BOOL POU_Grab_Pick FB VAR_INPUT
Yes Start_Drop BOOL POU_Grab_Drop FB VAR_INPUT
Yes TON_1 TON POU_Grab_Drop FB VAR
Yes M4 POU_Grab_Drop FB VAR_OUTPUT
Yes M5 TIME POU_Grab_Drop FB VAR
Yes R_Trig_0 RTRIG POU_Grab_Drop FB VAR
Yes Stop_Drop BOOL POU_Grab_Drop FB VAR_INPUT
Yes M6 BOOL POU_MANUAL PRG VAR
Yes M7 BOOL POU_AUTO PRG VAR
Yes M8 BOOL POU_AUTO PRG VAR
The program utilizes 24 Digital Inputs, 5 Digital Outputs, 23 Memory slots and 2 Timers.
PROGRAM
In the following pages, the program 1. Visualization_SortBySize
executed and printed from CoDeSys 2. POU: PLC_PRG
software has been presented. Please refer 3. POU: POU_AUTO
to the sheets with the following headers: 4. POU: POU_MANUAL
5. POU: POU_Grab_Pick
6. POU: POU_Grab_Drop
CONCLUSION
The program was executed to the
satisfaction of the project supervisor and
meets the logical and operational
requirements. It may be noted that the
grabber pick and drop operations have
been excluding from the scope of this
project due to insufficient data provided in
the project description. The scope of this
project can be further enhanced to include
in-depth mechanisms of the conveyor and
grabber operations.
This project is an excellent example of the
benefits in adopting automation. It can be
gauged from the programming logic that
multiple fail-safe, timing parameters,
conditional checks have been introduced
to improve efficiency, decrease throughput
time and smoothen work-flow which
would not have been possible with a
human based control structure.

RESOURCES
openpr.com
marketresearchfuture.com
techsciresearch.com
en.wikipedia.org
isa.org