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Application of PLCs

in Automation

Outline of Departments in BHEL


Block 1

Hydro Generator Engineering (HGE)

Block 2

Electrical Machines Group

Block 3

Transformer Engineering Division(TRE)

Block 4

Switchgear, Control gear and Rectifier (SCR)

Block 5

Foundry Shop

Block6

Coil Insulation & Manufacturing(CIM)

Block 7

Gas Plant

Block 8

Tool & Gauge Manufacturing(TGM)

Block 9

Traction Alternator Manufacturing(TAM)

Block 10

Casting and Press Shop

EMX Department (Electronics


Maintenance)
oBreakdown maintenance of machines
oRetrofitting / renovation and up gradation of old & obsolete controls with
state-of-the art systems.

oIn-house repair & testing of CNC controllers, drives, PLCs, and other
electronic items
oProgramming of PLC & CNC controllers.
oFraming specifications, technical reviews, involvement during E&C of capital
projects for Electronics / CNC based machines, plants and equipment.

EMX Department (Electronics


Maintenance)
oElectrically controlled machinery replaced by automated systems.
o BHEL has a vast array of such machines around 330 of them.
o The department is deputed for maintenance of such control panels, PLCs
and CNCs.
o A detailed study of these panels was done during the training program.
o Demo modules for control panels and PLCs were worked upon during the
schedule.

WHAT IS CNC RETROFITTING ?


OBJECTIVES
o Cost- effective modernization.

o Large size & costlier ageing machine tools need not be discarded.

FACTORS FOR SELECTION


o

Geometric accuracy.

Sound mechanical condition.

Availability of space on the machine.

Up gradation of obsolete CNC system.

ADDITION OF FEATURE / FACILITIES


o Complete reconditioning of the machine .
o State of the art CNC control system with PLC.
o AC/DC Digital/Analog servo feed drives for individual axes and Spindle.
o Linear/ Rotary position feedback systems.
o Automatic Tool Turrets/Changers.
o Hydraulic Power Packs ,Chucks & Tail-stock.
o Automatic Centralized lubrication system & Coolant with PLC.

ADVANTAGES OF CNC RETROFITTING


a new lease of life to the machine tools through

cost effective modernization

capability enhancement
addition

of facilities

restoration

of accuracies

quality improvement
better

accuracy

productivity enhancement by 100-200% by


cycle

time reduction

reduction

in rework / rejection

reduction

in down time

CNC (Computerized Numerical


Controller)
oProvide control information used to produce
parts.
oCNC controllers range in capability from
simple point-to-point linear control to highly
complex algorithms that involve multiple axes
control.
oCNC controllers configured to control greater
than six axes

CNC MACHINE TOOL (CLOSED LOOP SYSTEM)


CNC

PLC

NC

TACHO / POSITION
SENSOR
SERVO
DRIVE

BALL
SCREW

SERVO
MOTOR

S
P
I
N
D
L
E

JOB

VELOCITY
FEEDBACK

TABLE
POSITIONAL FEEDBACK

D N C LINK
TAPE READER
OTHER DEVICES

I/P
O /P

MACHINE ELEMENTS
DISPLAY UNIT
INPUT/OUTPUT
KEYBOARD
FLOPPY DISC / CD

ENCODER

PLC(Programmable Logic
Controller)
o Its an Industrial microcontroller system.
oProgrammed at Industrial site rather than
computer programmers.
o Block schematic is shown :

PLC(Programmable Logic
Controller)
How they are different from
microcontrollers:
oSpecial Input / Output arrangement using
modules .

oProgram memory is limited in


microcontrollers.
oProgramming language interoperability.

Agenda
Project Description
oIt showcases the fundamental use of Programmable Logic Controllers in Industrial
Automation integrated with Computerized Numerical Control Machines.
Project Methodology
oThe Siemens PLC is used as primary controlling element in the automation of oil
lubrication system in CNC machines
Key Findings/Results
o Manual lubrication has many pitfalls.
oPLC incorporated in machine is more efficient in terms of SAFETY & RELIABILITY
Conclusion
oPLCs provide flexible, error correctable, low cost solution to automation.

Project Description
Objective
o Control of lubrication systems in CNC machines using SIEMENS PLC SIMATIC S7300.
o It comprise of following main components : Controller , Pump & Reservoir, Supply Line,
Metering Valves, feed Lines .
o Control of following parameters is achieved :
o
o
o
o
o
o

On/Off switching
Oil level in tank
Oil pressure in pipes
Oil flow rate in pipes
Overload protection of pump & relays
Emergency condition

Schematic Diagram
of Automated Oil
Lubrication System

Procedure/Methodology
Procedure:

oPLC programming for process control .


oProgram is stored into user memory.
oCPU sequentially reads instructions & operate control.

oProgram can be written in 3 basic formats :


o
o
o
o
o

STL(Statement List)
SCF(Sequential Function chart)
LAD(Ladder Logic)- Most used
ST(Structured Test )
IL(Instruction List)

Procedure/Methodology
Key Assumptions:

oThe Oil lubrication is Set On for 30s and off or 5s assuming the following
conditions are met:o
o
o
o
o
o

Emergency button is not ON.


Overload relay is at correct switching position
Control button is ON
Oil level is adequate in tank
Oil pressure is above 6 bar.
Oil flow rate is above

PROGRAM : LADDER LOGIC


Programming language: STEP 7
Software: Simatic Manager
Assume the following:
IX.Y-INPUT
MX.Y-MEMORY BIT
QX.Y-OUTPUT
ONDT-ON DELAY TIMER
OFDT-OFF DELAY TIMER
TV-TIMER VALUE AS #SST<timevalue>
I0.0-Emergency button
I0.1-Control button (Push)
I0.2-Start
I0.3-Stop
I0.4-Overload relay
I0.5-Float switch
I0.6-Flow meter
I0.7-Pressure switch
I1.0-Contacator i/p

Q0.1- Contactor ON

LOGO!Soft Comfort - lubrication logic lad.pdf

M0.0, M0.1, M0.2,


M0.3, M0.4 are the
mem.bits used.

Data
observations

Data
Observations
54 percent of bearing failures
are contributed to inadequate
lubrication or contamination.
Too little lubrication, too
much lubrication", and not
often enough impact bearing
life significantly.

Project Summary

Manual Lubrication
oLoss of production due to downtime
o Labor for repair

o Replacement bearings and related materials


o Production labor cost
o Missed customer deliveries

o Increased safety issues when repairing machinery

Automated Lubrication
oIntegrated the reservoir, controller and fault monitor capability in one unit for design
simplicity installation cost reduction.

oDuring a lubrication cycle, the pump delivers lubricant through a supply line to the
metering devices.
oA lubrication cycle can be initiated by a PLC

oMonitor for proper system operation, blocked line detection and low-reservoir level.
oAlarm signals can be connected to a PLC, light or horn for remote notification.

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