Customized Industrial Programmable Controller

A PLC is a programmable logic controller that is utilized to provide controls of system without having to have whole switchboards of relays to perform the operation. A PLC Control can be use on many different kinds of process, from robotics to simple indicator panels. The primary function of the PLC

Project Title

Customized Industrial Programmable Controller

Project Area of Specialization

Electrical/Electronic Engineering

Project Summary

A PLC is a programmable logic controller that is utilized to provide controls of system without having to have whole switchboards of relays to perform the operation. A PLC Control can be use on many different kinds of process, from robotics to simple indicator panels. The primary function of the PLC Control, depending on the set points and controls that are designed into the system will allow the PLC to  Automatically control the system. By using inputs and outputs to control other devices, like relays, motors, and breakers etc. These inputs and outputs can be either be a digital signal or an analog signal depending on the type of PLC control that is designed. In the PLC there is a module that is the controller and this module has a program in it that is developed by the designer of the system with the PLC manufacture; software. This custom program is setup to read all of the inputs and to perform the necessary operations to control the outputs of the PLC to have the equipment respond in the manner the system is designed for the following basic function.

• 10A power relay rive for motor
• Digital I/O
• Analog I/O
• DAC Output
• PWM Output
• serial interface ports
• ethernet ports

Hardware can be Arduino/PLC based on electronic hardware board (compact PCB) or PLC with (All screw terminal). The operator will be able to control the system by the use of switches, push buttons, and touchscreen panels. These devices will have an input to the PLC Control and allow the PLC to make the appropriate change to the system when the operator initiates the action.   

Project Objectives

The Objectives of the project is designing and developing of low cost PLC for industrial automation and controlling. The number of PLCs exists but following key features differentiate our system from existing system
• Secured
• General purpose which cover all the functionality of industrial systems
• MATLAB based secured desktop application for automation and control of processes
• Ladder logic compiler in C++ for programming the PLC

The primary purpose of our system is to make a secure and indigenous PLC, which will be very fruitful in industrial automation and controlling systems. It takes data from sensors, switches and desktop application to Arduino UNO. As arduino acting as a master, so it gives commands to PIC18F452 slaves and they perform actions according to given command from desktop application.
For serial communication, we use Universal Asynchronous Receiver Transmitter (UART) protocol. As we are using UART protocol, we connect the TX pins of Arduino to RX pin of PIC18F452 and vice-versa. It transmits and receives data through data bus. We use arduino as a master controller and PIC as a slave controller and they communicate through UART protocol. Master/Slave controllers contain different component for driving output. Data is sending from slave to desktop application through master controller. We also control the status of slaves from desktop application. Input is given from desktop application to the Arduino and then it sends command to its PIC slaves and they perform action according to given command by master controller.

Project Implementation Method

For achieving our final product, we divide our project into many tasks. We perform these steps one by one for achieving our product, which are following:
• The first tasks was purchasing of products components including Arduino UNO, PIC18F452, sensors, switches, motors, water pump, LCD and relays.
• Next step knew the description of each and every components and their working.
• Third step was to establish communication between Arduino master and PIC single as well as multiple slaves through UART protocol.
• After communication, we have to connect different components with slaves like motor, digital input , digital output etc.
• Our fifth step was to develop our own MAtALB based desktop application for simulation and automation. Also, we have to make our own ladder logic compiler for ladder programming.
• Last step was the integration of hardware and software components.

Implementation Methodology
We use Agile methodology for implementing our project. First of all, we analyze our system and check that our system is feasible or not. After that, we ensure that it meet the requirements which we define earlier. After analyze of our system, we make plan about which protocol we should use for communication and which microcontroller is going to be master or slave. Then we design our system and we perform testing on each and every component until they work according to requirements. At last, we deploy our model after testing. With time according to changing requirements we can update our system easily. Agile software development refers to a group of software development methodologies based on iterative development, where requirements and solutions evolve through collaboration between self-organizing cross-functional teams, so we are following this methodology to design overall project.

Benefits of the Project

It is less vulnerable than SCADA, existing PLC and network devices. This Indigenous Secure PLC can be utilize in many industries like
• In Glass Industry, where PLC is used for controlling the material ratio, processing flat glasses and many other operations of this kind.
• In Paper Industry, when raw materials, water and chemicals are mixed together, requires high-tech tools such as PLC to achieve precise paper and production quality.

In our system architecture, we use Arduino as a master and PIC18F452 as a slaves. We use Universal Asynchronous Receiver Transmitter (UART) protocol for communication between master and slaves. UART contains extra bits like START bit, STOP bit, PARITY bit and they added to byte to be transmitted. As we use arduino as a master, so there are two pins we use for communication (TX, RX). The RX of master connected with the TX of slaves and TX of master connected with RX of slaves.In our system architecture, we use Arduino as a master and PIC18F452 as a slaves. We use Universal Asynchronous Receiver Transmitter (UART) protocol for communication between master and slaves. UART contains extra bits like START bit, STOP bit, PARITY bit and they added to byte to be transmitted. As we use arduino as a master, so there are two pins we use for communication (TX, RX). The RX of master connected with the TX of slaves and TX of master connected with RX of slaves.
• The accuracy is achieved in Cement Industry with the help of PLC's

• In the food industry, PLCs are used for automation on the production line
• A PLC bottle filling system allows the user to select the percentage selection volume, that uses the ladder language

Technical Details of Final Deliverable

Microcontroller (Arduino/PIC18F452)
To test arduino and PIC18F452, wires connecting to controllers were properly checked input, output, ground and power. All ports were checked and worked perfectly according to the code written. Working of circuit is tested and verified using Arduino/PIC simulator and emulator.

Temperature Sensor and Boiler Control
We are using LM35 temperature sensor for sensing the temperature of water. Sensor is properly checked and working properly according to requirements also we made it water proof. Data from the sensor is accurately displayed on the LCD which is connected with arduino (master) and also on the desktop application. Similarly Boiler is also working accurately in both automatic and manual mode and respond quickly as it receives any command.

Desktop Application (HMI)
For desktop application, testing is done by including library of junit  a framework along with Java programming language.
Unit testing is performed across application end where all components are working properly e.g buttons, automation panels and data communication between hardware and application. Database connectivity with application is properly checked as it maintains database in proper and efficient way and give out positive results.

Relays
In our project, we are using relays which are connected with microcontrollers PIC18F452 to operate the appliances. We used 220v operating lamp, heating rod or boiler and water pump which are controlled or connected by means of 5v relays and give positive results. All relays are working properly in system.

Final Deliverable of the Project

HW/SW integrated system

Core Industry

Energy

Other Industries

IT , Manufacturing

Core Technology

Robotics

Other Technologies

Others

Sustainable Development Goals

Good Health and Well-Being for People, Industry, Innovation and Infrastructure, Responsible Consumption and Production

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com