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LATHE MACHINE OPERATION

CONTROL
Introduction
Programmable logic controllers have applications in many different
fields like industry, homecare, transport, shopping malls, etc.., One
of the most important cache of PLCs used pretty well in the
industries is demonstrated in this project.
The operation of a lathe machine is dependent on the operations of
auxiliary units like lubrication motor and coolant pump.
The interlock of these three motors is best explained with the help of
PLCs which is also the main theme of the project.
Description
In a lathe machine, there are different gear trains for controlling the
forward and reverse movement of tool post or different movements
with respect to the axes.
To ensure long life of gears used in gear trains, special lubricating
arrangement is made which is run by a lubricating oil pump motor.
Unless the lubricating system starts functioning the main lathe
motor cannot be started. In addition to these, a coolant pump motor
for cooling of the job piece and the tool used for machining can be
started only after the first two motors having started their operations.
PLC is used here to control the sequential starting of the motors
providing necessary interlock.
Block Diagram

PLC
A programmable logic controller (PLC) or programmable
controller is a digital computer used for automation of
electromechanical processes, such as control of machinery on
factory assembly lines, amusement rides, or light fixtures.
PLCs are used in many industries and machines. Unlike
general-purpose computers, the PLC is designed for multiple
inputs and output arrangements, extended temperature ranges,
immunity to electrical noise, and resistance to vibration and
impact.

Basic operation of a plc

The basic elements of a PLC include input modules or points,
a central processing unit (CPU), output modules or points, and
a programming device. The type of input modules or points
used by a PLC depends upon the types of input devices used.
Some input modules or points respond to digital inputs, also
called discrete inputs, which are either on or off. Other
modules or inputs respond to analog signals. These analog
signals represent machine or process conditions as a range of
voltage or current values.

Fig : Major components of PLC

PLC Advantages
Flexibility: One single Programmable Logic Controller can easily run
many machines.
Correcting Errors: In old days, with wired relay-type panels, any program
alterations required time for rewiring of panels and devices. With PLC
control any change in circuit design or sequence is as simple as retyping the
logic. Correcting errors in PLC is extremely short and cost effective.
Space Efficient: Today's Programmable Logic Control memory is getting
bigger and bigger this means that we can generate more and more contacts,
coils, timers, sequencers, counters and so on. We can have thousands of
contact timers and counters in a single PLC. Imagine what it would be like
to have so many things in one panel.


Low Cost: Prices of Programmable Logic Controllers vary from
few hundreds to few thousands. This is nothing compared to the
prices of the contact and coils and timers that you would pay to
match the same things. Add to that the installation cost, the shipping
cost and so on.
Testing: A Programmable Logic Control program can be tested and
evaluated in a lab. The program can be tested, validated and
corrected saving very valuable time.
Visual observation: When running a PLC program a visual
operation can be seen on the screen. Hence troubleshooting a circuit
is really quick, easy and simple.

PLC Disadvantages
Fixed program applications: Some applications are single-function
applications. It does not pay to use a PLC that includes multiple
programming capabilities if they are not needed.
Fixed circuit operation: If the circuit in operation is never altered, a fixed
control system(such as a mechanical drum) might be less costly than a
PLC. The PLC is most effective when periodic changes in operation are
made.


Ladder logic programming
The biggest transition from relay control panels to PLCs was
the transition from the hard wired relay logic to logic defined
by user program. In order to allow established relay logic users
to program the PLC, a visual programming language that looks
like a relay control panel was created. This visual
programming language is called Ladder Logic.


Fig: Ladder logic programming
Delta PLC
Delta DVP-SS2 series PLCs. DVP-SS2 series PLCs include one 12-
point PLC, and two 14-point PLCs. A DVP-SS2 series PLC provides
various instructions, and the size of the program memory in it is 8k
steps. It is able to connect to all DVP-S series extension modules,
including digital I/O (max. 480 I/O points) and analog modules (for
A/D, D/A conversion and temperature measurement). 4 groups of
high-speed (10kHz) pulse output satisfy all kinds of applications.
DVP-SS2 is small in size, and can be install easily. Users do not
have to install any batteries in DVP-SS2 series PLCs.

Conclusion

Use of plc is demonstrated in manufacturing industry. In this
project the gear mechanism of the lathe machine is protected
by providing interlock. The main lathe motor cannot be started
unless the lubricant oil motor starts and lubricant system is
functional. Interlock is also provided for coolant pump motor
which does not start till the main motor starts thereby saving
the energy.
Thank you

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