Professional Documents
Culture Documents
in Automation
Block 2
Block 3
Block 4
Block 5
Foundry Shop
Block6
Block 7
Gas Plant
Block 8
Block 9
Block 10
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.
o Large size & costlier ageing machine tools need not be discarded.
Geometric accuracy.
capability enhancement
addition
of facilities
restoration
of accuracies
quality improvement
better
accuracy
time reduction
reduction
in rework / rejection
reduction
in down time
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 .
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:
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
Q0.1- Contactor ON
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
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.