AN ELECTRONIC CLOCK DISPLAY USING OMRON PLC TRAINER AND

PIC 16F877A

NURULAFIZA BT RAMLI

This report is submitted in partial fulfillment of the requirements for the award

of Bachelor of Electronic Engineering (Computer Engineering) With Honours

Faculty of Electronic and Computer Engineering

Universiti Teknikal Malaysia Melaka

April 2009

UNIVERSTI TEKNIKAL MALAYSIA MELAKA FAKULTI KEJURUTERAAN ELEKTRONIK DAN KEJURUTERAAN KOMPUTER

BORANG PENGESAHAN STATUS LAPORAh' PROJEK SARJANA MUDA I1

AN ELECTRONIC CLOCK DISPLAY USING OMRON

I1 TajukProjek : PLCTRAINERANDPIC 16F877A

Sesi : .............. .2008/2009.. ........................................... Pengajian

Saya ......................... NURULAFIZA BT RAMLI.. ................................................. (HURUF BESAR)

mengaku membenarkan Laporan Projek Sarjana Muda ini dishpan di Perpustakaan dengan syarat-syarat kegunaan seperti berikut:

1 . Laporan adalah hakrnilik Universiti Teknikal Malaysia Melaka.

2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja.

3. Perpustakaan dibenarkan membuat salinan laporan ini sebagai bahan pertukaran antara institusi

pengajian tinggi.

4. Sila tandakan ( d ) :

SULIT*

TERHAD*

,

TIDAK TERHAD

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat terhad yang telah ditentukan oleh organisasiroadan di mana penyelidikan dijalankan)

Disahkan oleh:

Alarnat Tetap: Lot 36 Kg. Sg. Deraka, Jalan Tanjung Lumpur, 25 150 Kuantan Pahang Darul Makmur

* (COP DAN TANDATANGAN PENYELIA)

FARlD ARAFAT BIN AZlDlN Pensyarah

Fskutti Kejuruteraan Elektronik Dan Kejuruteraan Kornpute~ Universiti Teknikal Malaysta Melaka (UTeLl)

Karung Berkunci No 1752 Pejabat Pos Durian Tunggal

76105 Durian Tunggal. Melaka

I Tarikh: ..... .30 April 2009.. ............ Tarikh: ..... .30 April 2009.. ..........

"I hereby declare that this report is the result of my own work except for quotes as

cited in the reference"

Signature : .......... Author

Date : 30 APRIL 2009

"I hereby declare that I have read this report and in my opinion this report is

sufficient in terms scope and quality for the award of Bachelor of Electronic

Engineering (Computer Engineering) With Honours"

QbP-P Signature : . . . . . . . . . . . . . . . . c.. . Name : MR FARID ARAFAT BIN AZIDIN

Date : 30 APRIL 2009

Special dedication to my beloved father and mom, my entire sibling and my kind

hearted supervisor Mr. Farid Arafat bin Azidin, and my dearest friends.

ACKNOWLEDGEMENTS

I would like to extend my sincere gratitude to my supervisor, Mr. Farid

Arafat bin Azidin, for her assistance and guidance toward the progress of this thesis

project. Through the year, Mr. Farid Arafat bin Azidin has been patiently monitoring

my progress and guided me in the right direction and offering encouragement.

Obviously the progress I had now will be uncertain without his assistance. My

special appreciation and thank to my friend Mohd Firdaus and Noor Roha for their

invaluable assistances towards this thesis project. I also would like to thank to my

family especially to my parents without their support and understanding this would

not have been possible.

ABSTRACT

The project aim was to a built an electronic board which detect signal from

Omron PLC trainer. A programmable logic controller (PLC) in an operating system

such as a machine includes a software development. The hardware part was based on

a simple circuit on Printed Circuit Board (PCB) with LCD display. The signals from

programmable logic circuit were transferred to PCB board as a time clock signal.

PIC 16F877A microcontroller was used as interface in order to display time clock on

LCD display. The electronic board also was designed with the voltage regulator to

step down the voltage, 24V form PLC to 5V. The software development started with

the flow chart, ladder diagram for PLC and finally, the software was written in C

language and implement on the PIC. As the result, whenever the PLC counting and

change the signal (clock), the LCD display will shown the output simultaneously

with the PLC.

ABSTRAK

Tujuan utama projek ini adalah membina satu litar elektronik yang marnpu

mengesan signal yang dihasilkan oleh Omron PLC. Litar eleckronik ini terdiri

daripada litar PCB dan paparan LCD Isyarat yang di hasilkan dari PCB board akan

dihantar ke litar untuk menghasilkan keluaran masa di paparan LCD. PIC16F877A

akan digunakan untuk menjana keluaran isyarat masa di paparan LCD. Litar

elektronik ini juga akan dilengkapi dengan litar voltage regulator untuk merendahkan

nilai voltage dr 24V kepada 5V. Pembangunan perisian akan dimulakan dengan

membina carta alir, gambarajah ladder dan di aplikasikan ke dalam PIC dalam

bentuk kod. Sebagai keputusannya, apabila terdapat perubahan isyarat dari PLC

maka isyarat yg diterima serta di hantar kepada paparan LCD secara serentak.

CHAPTER TITLE

PROJECT TITLE

DECLARATION 1

DECLARATION 2

DEDICATION

ACKNOWLEDGEMENT

ABSTRACT

ABSTRAK

TABLE OF CONTENT

LIST OF TABLES

LIST OF FIGURES

LIST OF SYMBOLS

LIST OF APPENDIX

I INTRODUCTION

1.1 Project Introduction

1.2 Objective Project

1.3 Problem Statement

1.4 Scope of Project

1.5 Methodology

1.6 Thesis Outline

PAGES

. . 11

. . . 111

iv

v

vi

vii . . .

Vlll

ix

xii

xiii

xv

xvi

I1 LITERATURE REVIEW

2.1 Definition PLC

2.1.1 Features of PLC

2.1.2 Ladder Logic

2.1.3 Discrete Input and Output System

2.2 Microcontroller

2.2.1 Identifying suitable Microcontroller

2.2.2 PIC 16F877A

2.2.3 Pin Description

2.2.4 Introduction to CCS C Compiler

2.2.5 Introduction to Proteus VSM 6.9

2.2.6 LCD Display

I11 METHODOLOGY

3.1 Flow chart

3.2 Project Planning

3 -2.1 Planning

3.2.2 Work Flow

3.3 Software Development

3.3.1 Introduction to CX-Programmer

3.3.2 Setting for Program

3 -3.3 Ladder Diagram Languages

3.3.4 System for the Content

3.3.5 Transfer to PLC

3.3.6 PLC Work Online Simulator

3.4 Hardware Development

3.4.1 Voltage Regulator

3.4.2 PIC 16F877A and LCD Display

IV RESULTS

4.1 Result Simulation Ornron PLC

4.2 Result Simulation PIC 16F877A

4.2.1 Schematic ISIS Professional

4.2.2 Program Code at CCS C Compiler

4.2.3 Win PIC Programmer

4.2.4 Voltage Regulator 7812

4.2.5 Voltage Regulator 7805

4.2.6 Etching at Positive PCB Board

4.3 Overall Result

4.3.1 Signal from Ornron PLC Trainer

4.3.2 Output LCD Display

4.3.3 Output An Electronic Clock

V DISCUSSION AND CONCLUSION

5.1 Conclusion

REFERENCES

xii

TABLE LIST

TABLE TITLE

2.1 PIC 16F877A 110 Pin Discretions

4.1 Output of PLC

4.2 Counter of PLC

4.3 Timer of PLC

PAGES

LIST OF FIGURES

FIGURES TITLE

... Xl l l

PAGES

Device of PLC

A Connection of Rung

A symbol of discrete output system

Von-Neumann Architecture

Harvard Architecture

PIC 16F877A

PIC 16F84 Microcontroller pin layout

LCD Display

Flow Chart of project methodology

CX-Programmed

Device and Network Type

Simulation PLC

Contact and Coil

Timer Header

Timer Bit and Value

Component in Proteus

Schematic Diagram PIC 16F877A

CCS C Compiler

Mnemonics Code

LCD Display

Win PIC Programmer

Simulation Voltage Regulator 78 12

Circuit Voltage Regulator 78 12

Simulation Voltage Regulator 7805

Circuit Voltage Regulator 7812 and 7805

Etching circuit LCD Display

4.9 Etching Circuit Voltage Regulator

4.10 Troubleshooting Signal from PLC

4.1 1 Signal Generator

4.12 Circuit PIC 16F877A and LCD Display

4.13 Final Circuit

LIST OF SYMBOLS

PLC - Programmable Logic Controller

PIC - Peripheral Interface Circuit

I/O - Input and Output

LCD - Liquid Crystal Display

LIST OF APPENDIX

NO TITLE

A LADDER DIAGRAM FOR CX-PROGRAMMER

B DATASHEET PIC 16F877A

PAGES

CHAPTER I

INTRODUCTION

1.1 Project Introduction

Programmable logic controllers (PLC) have gained a very strong position in the

industrial automation field. The growing complexity of the applications of PLC strongly

depends on programmers and maintenance personnel. Hence, PLC education is a great

demand nowadays. Programmable logic controllers (PLC) were originally design to

control processes that required a sequence of events to be follow. Today, PLCs have

advanced to the stage of being incorporate in SCADA (Supervisory Control and Data

Acquisition) systems, continuous control systems. In industry, there are several

manufacturers of PLCs, most of the instruction formats of PLC may not the same for

different brands, but the hardware structures and programming concepts are very similar.

For this project, the PLC was used to generate time clock and monitor the functional of

electronic device. The signal from the PLC will be integrated at an electronic board,

which is containing voltage regulator, LCD display and PIC 16F877A. In order to

display the clock, PIC 16F877A was used to receive and analyze signal from PLC. This

system provides a user friendly graphical interface and allowing analysis of PLC

program and implemented in the real time simulation.

1.2 Objective of Project

The main objective of this project is to design an electronic board with the

capability to detect the signal from PLC and generate output time clock at LCD display

by using PIC 16F877A within the required timeline and also to develop programming

code based on PIC based system to support application of LCD display.

1.3 Problem Statement

In the virtual PLC, the program is written using the Relay Ladder Language and

supported by the programming editor. In run mode, the PLC makes its simulation of the

ladder program based on its input and the program and displays the output. However, the

output that has been generated was not easy to identify since the PLC just give the

output by shown it based on the lightning of button output. In order to apply the

application on PLC, it is needed to make sure PLC can be a user friendly system so that

user can analyze the output easily. Therefore, for this project, as we know PLC can

generate time clock however, it did not provide any display system for the user. Hence,

it is necessary to integrate the PLC with other display system that is LCD display. In

order to display using LCD display it is use PIC 16F877A as it interface to receive the

signal from the PLC. In addition, the communication between PLC and PIC is a new

innovation part in the industry since, people can see the growth in the technology if the

two different technology was combined. Hence the complexity of the design can be

develop and improve the features of the technology.

1.4 Scope of Project

I. Literature study on the PLC program to identify how to use CX-program and

develop ladder languages foe generate time clock.

11. Study the signal generated from PLC based on Ladder Programming.

111. Literature study on the Proteus VSM 6.0 to know how to use PIC 16F877A.

IV. Study on Proteus VSM 6.0 to understand the application of PIC to display

output by using LCD display.

V. Develop and analyze the program efficiently in C programming language and

by using ISIS 6 professional.

VI. Design, and built an electronic board which can detect signal form Omron

PLC trainer and can display the output at LCD display by using PIC

16F877A.

VII. Integrate between the hardware and software after all design completed.

1.5 Methodology

Phase1:-

Identify the problem statement, which is how to generate time clock by using

Omron PLC trainer and how to display the clock at LCD display by using PIC16F877A.

Phase2:-

Make a literature review for the project system including study about the

component that will be use, their characteristic and understand deeply about the circuit

and how it operates and analyze the datasheet of component involved such as (PLC,

voltage divider, PIC and LCD display).

Phase3:-

For this phase, it called as software development, where involve analyze and

study to design a ladder diagram by using CX-program to generate time clock and

simulation PIC 16F877A by using Proteus VSM 6.9 to display the output at LCD

display.

Phase4:-

For this phase, it called as hardware design. There are two phase for hardware

design, which is Voltage regulator's circuit,PIC 16F877A and LCD's circuit. All

components must have extra features to make sure the troubleshooting circuit can be

done easily.

Phase5:-

For this final phase, it called performance test. In this phase, the software part

and hardware part need to be combining together to get the result and to achieve the

objective of project. The final results is then being compared with the theoretical. After

that, the circuit that already constructed will be tested its functional, ability & weakness.

If there is any error detected, the troubleshooting process will be done in order to make

sure the circuit is well functioning.

1.6 Thesis Outlines

This thesis consists of five chapters. The following chapters are the outline of the

implementation of an electronic board which can detect signal form PLC to generate

time clock and display the output at LCD display by using PIC 16F877A.

Chapter I Will discuss briefly the overview of this project such as introduction,

objectives, methodology and thesis outlines.

Chapter I1 Contains the research and information about the project on several

important concepts of ladder diagram on PLC, C-programming language on PIC

16F877A, technology and tools in the study. Every facts and information, which found

through journals or other references, will be compared and the better methods have been

chose for the project.

Chapter 111 Includes the detail about designing and programming to generate

time clock system by using PLC and to display the output at the LCD display.

Simulation results, analysis, observation and discussion of the performance to generate

time clock technique are presented in.

Chapter IV Includes the detail about the hardware design involved schematic

diagram, PCB layout, components required and working principle for each circuit

especially for circuit PIC 16F877A and LCD display.

Chapter V Describes more about the discussion, and project findings. The result

is then presented in figures or plotted graph. This chapter also discuss about the

conclusion of the project and the future recommendations.

CHAPTER I1

LITERATURE REVIEW

This chapter contains the research and information about the project on several

important concepts of ladder diagram on PLC, C-programming language on PIC

16F877A, technology and tools in the study. Every facts and information, which found

through journals or other references, has been compared and the better methods have

been choosing among them

2.1 Definition of PLC

A Programmable Logic Controller (PLC) also referred to as programmable

controller. It is the name given to a type of computer commonly used in commercial and

industrial control applications. PLC have been gaining popularity on the factory floor

because of the advantages they offer such as:

a) Cost effective for controlling Complex system.

b) Flexible and can be reapplied to control other system quickly and easily.

c) Computational abilities allow more sophisticated control.

d) Reliable components make these likely to operate for years before failure.

e) Troubleshooting aids make programming easier and reduce downtime.

PLC is different from office computers in the types of tasks that they perform

and the hardware and software they require performing these tasks. While the specific

applications changeable widely, all PLCs monitor inputs and other variable values and

make decisions based on a stored program, and control outputs.

The basic operation and elements of a PLC is including input models (points), a

central processing unit (CPU). Output models (points) and a programming device. For

the input models of PLC it is depends upon the types of input devices used. Some of the

input models respond to digital input (discrete inputs) and other input models respond to

analog signals. The primary function of a PLC circuitry is to convert the signal provided

by these various switches and sensor into logic signal that can be used by the CPU.

The CPU evaluates the input, output, and other variables and executes as a stored

program. The CPU sends signals to update the status of the output. Output modules will

convert control signal from the CPU into digital values that can be used to control a

various type output devices. While the programming device is used to change the PLC's

program, monitor and change stored values.

2.1.1 Features of PLC

The main difference from other computers is that PLC is armored for severe

condition such as dust, moisture, heat, cold and ext which have the facility for extensive

input/output (I/O) arrangements. These connect the PLC to sensors and actuators. PLCs

read limit switches, analog process variables such as temperature and pressure and the

positions of complex positioning systems. On the actuator side, PLCs operate electric

motors, pneumatic or hydraulic cylinders, magnetic relays or solenoids, or analog

outputs. The input/output arrangements may be built into a simple PLC or the PLC may

have external 110 modules attached to a computer network that plugs into the PLC.

PLCs were invented as replacements for automated systems that would use hundreds or