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Submitted By:

PRIYA HADA

B.Tech. ECE Semester VII

A Presentation

on Summer Training

in

PLC & Scada

Submitted To:

Ms. Pushpa GothwalFaculty of ASET

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1. Programmable Logic Controller Project (PLC)

A Pharmaceutical plant

2. Supervisory Control And Data Acquisition Project (SCADA)

Bottle Filling & Capping Station

ASET

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ASET

Figure1 : Block Diagram of PLC System

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Project Using PLC: A Pharmaceutical

plant

OBJECTIVE : To design a pharmaceutical plant using Programmable

Logic Controller for manufacturing of a medicine in which two different

liquid should mix in equal quantity and then this mixture should be heat for

20 seconds on a constant temperature of 100 C.

Hardware and Software Used:1. PLC: Allen Bradley Micro Logix 1000 with 10 Input / Output.

2. Programming Software: Rockwell software RS Logix 500 English

3. Communication Software: RS Linx.

4. Programming Language: Ladder Logic.

5. Communication Protocol: RS 232

6. Other Hardware: Push Buttons, Light Emitting Diode.

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FLOWCHART

Working of Project:

The process involves mixing of two different

liquids in equal quantities.

The process is start by pressing the START

button.

When the START button is pressed, the two

liquids starts mixing, this is indicated by

glowing of two output LED.

Next, after a time lapse of 20, seconds the

third LED glows indicating that the mixture is

heated for 20 seconds, at 100 C.

STOP button is pressed to stop the process.

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Figure 2: Ladder diagram in De-energize state.

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Figure 3:The process is start by pressing the START button.

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Rung 0000 :The START switch is represented by XIC I:0/0 and the STOP switch

is represented by XIO I:0/1. I represent input. The output is a binary bit B3:0/0.When

START button is pressed the input I:0/0 is HIGH and input I:0/1 is already HIGH

because its XIO. This energizes the output B3:0/0.

Rung 0001 : B3:0/0 acts as input to the TON timer T4:0/0 with preset value 30

and accumulator value 0.

Rung 0002 : B3:0/0 acts as the input to two parallel outputs O:0/0 and

O:0/1.These outputs represent the output LED. Two liquids are being mixed in a

container

Rung 0003 : (a)The DN bit of timer T4:0 i.e. T4:0/DN acts as input to the timer

T4:1.

(b) This T4:1 indicates the time for which the mixture of the two liquids

is to be heated at 100 C.

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Figure 4: T4:0 goes HIGH and timer T4:1 starts to increase

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Rung 0003:

(a) As stated above when accumulator value becomes equal to the preset

value the DN bit of the timer T4:0 goes HIGH. When this happens the

accumulator value of TON timer T4:1 starts to increase till it

reaches the value equal to that of preset (=20).

Rung 0004:(a) The DN bit of T4:1 i.e. T4:1/DN is connected to the output O:0/2.

The O:0/2 represents the third output LED.

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Figure 5: The glowing of third LED indicated that the heating of the mixture is

completed.

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As soon as T4:1/DN goes HIGH, the output O:0/2 is energized and the third LED

starts to glow.

(b) The glowing of third LED indicated that the heating of the mixture is

completed.

(c) After this the STOP button (I:0/1) is pressed i.e. XIO I:0/1 goes LOW and the

whole process is reset.

ResultsThe two liquids were mixed (indicated by glowing of first two LED) and the mixture

was heated for 20 seconds (indicated by glowing of the third LED).

Future Scope1. When connected with SCADA using the Device Connectivity feature of SCADA,

the project can implemented with Recipe Management feature of SCADA. This way

we can change the ingredients of the mixture.

2. This project can be extended to filling of the mixture into different bottles then

labeling and packing them i.e. making a fully automated medicinal syrup

manufacturing plant.

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Project Using SCADA : Bottle

Filling & Capping Station

Project Objective : To design a ”Bottle filling and Capping Station”

using Wonder ware Intouch SCADA.

Software Used : Wonderware Intouch version 9.0.

Working of Project:The project is made in Window Maker and executed in Window Viewer. In

window viewer, the project would run as:

When the switch is turned on, a bottle will be filled to full by three different tanks

filled with different liquids as indicated by their color.

Liquid poured to the bottle when its presence under the tank is sensed.

Then a clamper brings down the cap to the mouth of bottle, places it there and then

returns back to its original position.

The bottle is capped is then moved to the storage.

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1. In the Intouch Application Manager, select file New Create new Application.

This creates a new Intouch application.

2. Double click on this application, it opens Intouch Window maker.

3. In Window maker we select File New Window. A dialog box appears asking for

name, window type, window color and other properties.

4. We name the window as ”bottle fill transfer”, window type as replace , frame

style as single and click on OK. A window appears as per defined by us.

5. Wizard icon Wizard Selection window graphical objects.

6. Wizard Selection window symbol factory option double click

8. In the symbol factory window there are various categories of the graphical

objects like Tanks, Containers etc. We select the different objects as per

our requirement.

Programming ASET

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15Figure 6: The finished window is shown as below: 5 different bottles are shown .

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For all the objects taken from the symbol factory, we perform Break Cell operation

so that we are able to change their properties as per our requirement. Following is the

figure showing the list of the properties available for each object from Symbol

Factory:

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Figure 7: list of the properties

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We see that there are different bottles under the tanks whereas in the run time we

require only one of them. This is done keeping in mind the visibility of each bottle.

Filling of the Bottle ASET

Figure 8: Filling of the bottle

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Capping of the BottleASET

Figure 9: Capping of the bottle

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Figure 10 : Bottle is sent to storage after its filling and capping.

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Since there is no manual work i.e. no

slider is being used, window script

has to be used for incrementing the

value of the counter, whose tag name

is used as the expression for all other

objects.

There are two parts in the script:

(a) On Show: how the things should

appear as soon as the window

viewer is started.

(b) While showing: how things will

appear once the task starts to run

on window viewer.

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Figure 11 :Window Script.

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ResultsThe design of ”Bottle Filling and Capping Station” is successfully implemented

in Intouch SCADA.

Future ScopeThis project can be implemented practically when SCADA is connected with

PLC. More enhanced features can be added up to it. Some features are:

1. Automatic Labeling of Bottles.

2. Defected Bottles such as bottles without cap or less in weight should be

automatically removed.

3. Automatic pick up of bottle after filling it up.

ASET