PLC Based Automatic Oil Filling Machine - IJSRD

IJSRD - International Journal for Scientific Research & Development Vol. 2, Issue 02, 2014 ISSN (online): 2321-0613PLC based Automatic Oil Filling MachineBhumika I. Patel1 Riddhi S. Patel2 Krutika T. Patel3 Prof. K. G. Bhuva41, 2, 3, 4Electronics & Communication Engineering Department1, 2, 3, 4Goverment Engineering College (G.T.U.) - 392002, Gujarat, India.Abstract--- The main aim of this project is to provide a lowcost automated oil filling system. The present system willprovides a great deal of applications in the field of low costautomation, especially in mass production industries wherethere are large number of components to be processed andhandled in a short period of time and there’s need forincreased production.Keywords: automatic oil filling machine, PLC, hardware,low cost automation.I. INTRODUCTIONIndia is fast developing industrially. The industrial growth,particularly during the last decade, has been considerable.This growth, of course, is not free from the attendantproblems. In a country like ours, which has mainly anagricultural based economy, the industrial development isvery likely to change the existing conditions.In our country, one can come across factories withoutdated and inefficient technology and also factories withmodern and highly sophisticated technology. The mainreason for the latter is the fact that the latest technologicaldevelopments from the already developed countries havebeen transplanted is worthwhile to remember that thetechnological advancement that has taken place in thedeveloped countries has been, achieved in stages, dependingupon the changed conditions and requirements. For examplemany of the developments in industrially more advancedcountries require minimum labor force because of the factthat increasing wages, shortage of skilled labor force andlower Productivity have made the older technologiesinadequate to meet the demands, inefficient, anduneconomical.A. Low Cost AutomationLow Cost Automation (popularly known as LCA), is theintroduction of simple pneumatic, hydraulic, mechanical andelectrical devices into the existing production machinery,with a view to improving their productivity.Fig. 1: AutomationThis would also enable the operation of this equipment byeven semi-skilled and unskilled labor, with a little training.This will involve the use of standardized parts and devicesto mechanize or automate machines, processes and systems.Utilizing a human being as a source of energy is aninefficient method, in addition to being boring andmonotonous to the worker.The aim of the project is to fill oil to three differentheight compressors. This type of filling is used in manyindustries. By this process, we are able to fill the differentclasses of objects. With the advent of liberalization andglobalization, it is necessary that industries explore methodof enhancing automation.B. History of PLC:Before the PLC, control, sequencing, and safety interlocklogic for manufacturing automobiles was mainly composedof relays, cam timers, drum sequencers, and dedicatedclosed-loop controllers. Since these could number in thehundreds or even thousands, the process for updating suchfacilities for the yearly model change-over was very timeconsuming and expensive, as electricians needed toindividually rewire relays to change the mable devices, were soon applied to control ofindustrial processes. Early computers required specialistprogrammers, and stringent operating environmental controlfor temperature, cleanliness, and power quality. Using ageneral-purpose computer for process control requiredprotecting the computer from the plant floor conditions. Anindustrial control computer would have several attributes: itwould tolerate the shop-floor environment, it would supportdiscrete (bit-form) input and output in an easily extensiblemanner, it would not require years of training to use, and itwould permit its operation to be monitored. The responsetime of any computer system must be fast enough to beuseful for control; the required speed varying according tothe nature of the process.[1]In 1968 GM Hydra-Matic (the automatictransmission division of General Motors) issued a requestfor proposals for an electronic replacement for hard-wiredrelay systems based on a white paper written by engineerEdward R. Clark. The winning proposal came from BedfordAssociates of Bedford, Massachusetts. The first PLC,designated the 084 because it was Bedford Associates'eighty-fourth project, was the result.[2] Bedford Associatesstarted a new company dedicated to developing,manufacturing, selling, and servicing this new product:Modicon, which stood for Modular Digital Controller. Oneof the people who worked on that project was Dick Morley,who is considered to be the "father" of the PLC.[3] TheModicon brand was sold in 1977 to Gould Electronics, andlater acquired by German Company AEG and then byFrench Schneider Electric, the current owner.All rights reserved by www.ijsrd.com111

PLC based Automatic Oil Filling Machine(IJSRD/Vol. 2/Issue 02/2014/031)One of the very first 084 models built is now ondisplay at Modicon's headquarters in North Andover,Massachusetts. It was presented to Modicon by GM, whenthe unit was retired after nearly twenty years ofuninterrupted service. Modicon used the 84 moniker at theend of its product range until the 984 made its appearance.The automotive industry is still one of the largestusers of PLCs.C. Programming:Early PLCs, up to the mid-1980s, were programmed usingproprietary programming panels or special-purposeprogramming terminals, which often had dedicated functionkeys representing the various logical elements of PLCprograms.[2] Some proprietary programming terminalsdisplayed the elements of PLC programs as graphicsymbols, but plain ASCII character representations ofcontacts, coils, and wires were common. Programs werestored on cassette tape cartridges. Facilities for printing anddocumentation were minimal due to lack of memorycapacity. The very oldest PLCs used non-volatile magneticcore memory.More recently, PLCs are programmed usingapplication software on personal computers, which nowrepresent the logic in graphic form instead of charactersymbols. The computer is connected to the PLC throughEthernet, RS-232, RS-485 or RS-422 cabling. Theprogramming software allows entry and editing of theladder-style logic. Generally the software provides functionsfor debugging and troubleshooting the PLC software, forexample, by highlighting portions of the logic to showcurrent status during operation or via simulation. Thesoftware will upload and download the PLC program, forbackup and restoration purposes. In some models ofprogrammable controller, the program is transferred from apersonal computer to the PLC through a programming boardwhich writes the program into a removable chip such as anEEPROM or EPROM.D. Functionality:The functionality of the PLC has evolved over the years toinclude sequential relay control, motion control, processcontrol, distributed control systems and networking. ation capabilities of some modern PLCs areapproximately equivalent to desktop computers. PLC-likeprogramming combined with remote I/O hardware, allow ageneral-purpose desktop computer to overlap some PLCs incertain applications. Regarding the practicality of thesedesktop computer based logic controllers, it is important tonote that they have not been generally accepted in heavyindustry because the desktop computers run on less stableoperating systems than do PLCs, and because the desktopcomputer hardware is typically not designed to the samelevels of tolerance to temperature, humidity, vibration, andlongevity as the processors used in PLCs. In addition to thehardware limitations of desktop based logic, operatingsystems such as Windows do not lend themselves todeterministic logic execution, with the result that the logicmay not always respond to changes in logic state or inputstatus with the extreme consistency in timing as is expectedfrom PLCs. Still, such desktop logic applications find use inless critical situations, such as laboratory automation anduse in small facilities where the application is lessdemanding and critical, because they are generally muchless expensive than PLCs.II. PROGRAMMABLE LOGIC CONTROLLERS (PLC)PLC can be defined as a digital electronic device that uses aprogrammable memory to store instructions such as logic,sequencing, timing, counting and arithmetic to control of aPLC was to directly replace electromechanical relays aslogic elements machines or processes. The purposesubstituting instead a solid digital computer with a storedprogram, able to emulate the interconnection of many relaysto perform certain logical tasks.Fig. 2: PLCA Programmable Logic Controller, PLC orProgrammable Controller is a digital computer used forautomation of electromechanical processes, such as controlof machinery on factory assembly lines, amusement rides, orlight fixtures. PLCs are used in many industries andmachines. Unlike general-purpose computers, the PLC isdesigned for multiple inputs and output arrangements,extended temperature ranges, immunity to electrical noise,and resistance to vibration and impact. Programs to controlmachine operation are typically stored in battery-backed-upor non-volatile memory. A PLC is an example of a hard realtime system since output results must be produced inresponse to input conditions within a limited time, otherwiseunintended operation will result.A. PLC SoftwareBosch Rexroth IndraLogic PLCs are used to build PLCsprogramming in Ladder logic. IndraWorks is the carriersystem for integration of the Bosch Rexroth engineeringtools. Rexroth IndraLogic is based on the CoDeSystechnology of Smart Software Solutions (3S). IndraLogic1.32 is based on CoDeSys version 2.3, service pack 4.IndraLogic puts a simple approach to the powerful IEC61131-3 language at the disposal of the PLC programmer.The IEC 61131-3 international standard defines four PLClanguages: ladder logic, sequential function charts, functionblocks, and a text language. By far, ladder logic is the mostAll rights reserved by www.ijsrd.com112