Design and construction of a PLC trainer

Project Title

Design and construction of a PLC trainer

Project Area of Specialization Electrical/Electronic EngineeringProject Summary

Introduction:- 

                    A Programmable Logic Controller is the name given to a type of computer systems commonly used in commercial and industrial control applications. PLCs can differ in sizes and types with the types of tasks that they perform and the hardware and software they require performing these tasks. Such tasks are essential to taught and learn as it becomes an integral part of modern industrial automation. For this a PLC trainer is introduced.                   

 A PLC trainer is Programmable Logic Controller training system which contains specialized programming software for creating workable logic. A PLC trainer is great for students in technical schools, colleges and Universities who start to learn PLC programming. There are many PLC training kits based on different control units i.e. Allen Bradley, Siemens, Mitsubishi etc.

Considering financial, technical and industrial needs i have prepared a PLC comprises of the CPU from Delta. It is a self-contained trainer which consists of a DVP series of 30ex2 and commonly used I/O devices for simulations. It offers students excellent theories and wide applications of programmable logic controllers. The trainer enables students to learn step by step from the fundamentals of PLC to more advanced controls used in industry.

Control Unit:-

30 Ex 2 has many advantages first of all it has built in Analog channel and RTD channel which helps it do many task at a time because in other PLCs we have connect these channels then we can perform task on Analog channels like connecting sensors and different things of anaolg channel but by using this type of PLC we got these two things already connected.RTD channel is also very important in industry due to the temperature measurement of machines in the industries RTD sensor can measure temperature upto 600 to 800 degree celcius and after that we use thermocouple in the industry.It has 16 inputs and 10 ouputs but in other plcs like 20ex2,16ex2 have only 8 inputs and 8 outputs so 30ex2 is also good in inputs and outputs.It is a relay type PLC means that its response time is somehow slow it is not transistor type because we donot need fast response in delta plc so that we use relay type plc in our trainer board.

Components:-

Our plc trainer is embedded with multiple industrial automation techniques.For this purpose it carries many components to fulfill its needs.

• Push Buttons
• Indicator Lamps
• Toggle Switches
• Selector switches
• 4-Pole Relay
• Delta PLC
• HMI
• Emergency Breaker
• 24 volt fixed DC power supply
• Banana Cables
• RS-232 Protocol 

Easy To Use:-

We have developed a trainer with keeping in mind the easiness of the end user.Hence the modulator design makes it flexible for the use in technical colleges and universities.Modulator provides the ability to add the additional I/Os without increasing the CPUs footprints.

Project Objectives Minimizing the Learning Curve

Now, for those of you who work with PLCs but are just starting out, PLC training is a great way to get ahead of the curve. I was very fortunate when I started my Controls Engineering career. A local company took me in and showed me everything there was to know about PLCs and PLC programming. But if you don’t have someone available to train you, there are many places that offer PLC training. And with PLCs, a little training can go a long way. Even the slightest hands-on experience can further your understanding and get you ready for the career ahead.

Staying Ahead of the Game

“I work with PLCs every day, I don’t need training.” Like any technology, PLCs are constantly advancing and keeping up with new developments can benefit you as well as your company. These days the minute you buy the newest technology it is on its way to being obsolete. PLCs are no different. Advances in hardware and software are making PLCs more efficient, user friendly and cheaper. For instance, a lot of controllers can now interface with mobile apps for remote monitoring, something that wasn’t available when I was trained. It is always a good idea to stay informed of what may be coming next.

Keeping Your Options Open

“I don’t work with PLCs at all, I don’t need training.” Maybe not. But allow me to give you some things to consider. First, a lot of companies are turning to automation to stay profitable. An understanding of what automation is and how it works could afford you the knowledge of how to automate some of the processes you do work with, saving you time and your company money. Besides that, it is always good to have a plan B for your career and PLC training can give you the mobility to move to another career field in case the need arises.

Furthering Your Education

Three words: continuing education credits.You better know what I’m talking about.

PLCs are Your Friend

Engineering is the science of solving problems. Electrical Engineering is solving those problems electrically. Automation was born to solve problems faced by production facilities but it can also be used to solve problems at home. Learning the basics of PLC technology can give you the knowledge to automate tasks performed around the house. Personally, I use a PLC system to water my garden twice a day. What might you do to use it.

Can Be Sale To Market:-

After making it i can easily sale it as a product to the Technical institutes and make money from this.Because it has a big demand in industry so that i can make trainers to meet the industrial demands.

Project Implementation Method

First of all i have learned the AutoCad to make the design of the trainer then i make the design of it and then i choose the components to make the PLC trainer and the list of the components are  

• Push Buttons
• Indicator Lamps
• Toggle Switches
• Selector switches
• 4-Pole Relay
• Delta PLC of 30ex2
• HMI
• Emergency Breaker
• 24 volt fixed DC power supply
• Banana Cables
• RS-232 Protocol                                                    30 Ex 2 Delta PLC of DVP series:-

  30 Ex 2 has many advantages first of all it has built in Analog channel and RTD channel which helps it do many task at a time because in other PLCs we have connect these channels then we can perform task on Analog channels like connecting sensors and different things of anaolg channel but by using this type of PLC we got these two things already connected.RTD channel is also very important in industry due to the temperature measurement of machines in the industries RTD sensor can measure temperature upto 600 to 800 degree celcius and after that we use thermocouple in the industry.It has 16 inputs and 10 ouputs but in other plcs like 20ex2,16ex2 have only 8 inputs and 8 outputs so 30ex2 is also good in inputs and outputs.It is a relay type PLC means that its response time is somehow slow it is not transistor type because we donot need fast response in delta plc so that we use relay type plc in our trainer board.

   HMI:-

  Human-machine interface (HMI) is a component of certain devices that are capable of handling human-machine interactions. The interface consists of hardware and software that allow user inputs to be translated as signals for machines that, in turn, provide the required result to the user. Human-machine interface technology has been used in different industries like electronics, entertainment, military, medical, etc. Human-machine interfaces help in integrating humans into complex technological systems.

  Human-machine interface is also known as man-machine interface (MMI), computer-human interface or human-computer interface. 

•  Push Button:-

• A push-button (also spelled pushbutton) or simply button is a simple switch mechanism to control some aspect of a machine or a process.

• 24 volt Power Supply:-

• We give 24volts to PLC to give input to the switches and our PLC is also run in 24 volts.

• Breaker:-

  Breaker is used to save our PLC trainer,if high voltages come so breaker will save our HMI and PLC and switch off the whole trainer imidiately.

• Miniature Relays:-

  It is 14 pin relay it has different NO,NC contacts means 1 relay can be used for many contacts it has 4 NO ,4NC, 4 common and 2 pins called A1,A2 which energieses the relay it is 24volt operated and 220volt operated means AC and DC both can run on it.Relays is used for the switching purpose and need to turn on things on 220V and 24V.

Benefits of the Project

The three letters that has more weight is PLC and may be in size it looks small, but in career side, it seems to be more weight and beneficial. What are the students now expecting after they completed their degree? A Secured job with good salary and monetary benefits is what they expecting. Yes, it is a true fact, job security is essential and a job that does not satisfy this aspect does not seems to be a good one. Some part of the students expects the thing that i said above and some part of them may expect knowledge along with the above benefits. These are the two categories and a job that satisfies the two categories of students i s said to be a best one. So the automation industry is the best one if you prefer for the job that i said above.

So to enter into such industry, you need to be trained well with software's and applications that deal with the automation industry. PLC training is essential if you prefer to enter into automation industry. PLC is very famous in Chennai and many students call it as PLC Chennai due to various plc training centers available here. It is true and sure fact that it is not easy to enter into any field unless you are well capable of doing it. So don't be like a dumb goat in the crowd and try to learn many new things and keep your mind always updated. Mind is like an evergreen tree and as how a tree looks always green when you pour water continuously similarly pour the knowledge to your mind in a continuous manner and try to be evergreen always. PLC training enables you to get updated regularly and once you learned, you will be interested in this field and this interest enables to improve to yourself.

You learn many logic things and also the people can learn programming concepts that gives you interest to learn and automatically you will implement many new things in your field. So try to learn PLC automation training and it benefits you in all aspects. Try to learn PLC training in Chennai because in Chennai there are many PLC automation training centers that teaches and recruit you in good industries with decent salary and job security. They add value to your life through their world class service and through their standards. The PLC training centers in Chennai should have experience in the respective fields and should provide faster service with greater reliability and they should make your dream to come true.

Most of the candidates prefer for PLC training in Chennai because the PLC training centers in Chennai provide compulsory placement and that too in good industries. The second reason is that they teach and train well in this field with good lab facilities and train completely in the industrial automation using PLC, scada, relays and make them completely suit for the automation industries.

Technical Details of Final Deliverable We will provide finally these technical Deliverable to the User:

30 Ex 2 has many advantages first of all it has built in Analog channel and RTD channel which helps it do many task at a time because in other PLCs we have connect these channels then we can perform task on Analog channels like connecting sensors and different things of anaolg channel but by using this type of PLC we got these two things already connected.RTD channel is also very important in industry due to the temperature measurement of machines in the industries RTD sensor can measure temperature upto 600 to 800 degree celcius and after that we use thermocouple in the industry.It has 16 inputs and 10 ouputs but in other plcs like 20ex2,16ex2 have only 8 inputs and 8 outputs so 30ex2 is also good in inputs and outputs.It is a relay type PLC means that its response time is somehow slow it is not transistor type because we donot need fast response in delta plc so that we use relay type plc in our trainer board.

HMI:-

Human-machine interface (HMI) is a component of certain devices that are capable of handling human-machine interactions. The interface consists of hardware and software that allow user inputs to be translated as signals for machines that, in turn, provide the required result to the user. Human-machine interface technology has been used in different industries like electronics, entertainment, military, medical, etc. Human-machine interfaces help in integrating humans into complex technological systems.

Human-machine interface is also known as man-machine interface (MMI), computer-human interface or human-computer interface.

Push Button:-

A push-button (also spelled pushbutton) or simply button is a simple switch mechanism to control some aspect of a machine or a process.

Miniature Relays:-

It is 14 pin relay it has different NO,NC contacts means 1 relay can be used for many contacts it has 4 NO ,4NC, 4 common and 2 pins called A1,A2 which energieses the relay it is 24volt operated and 220volt operated means AC and DC both can run on it.Relays is used for the switching purpose and need to turn on things on 220V and 24V.

RS-232 Protocol:-

RS232 was introduced in 1960’s and was originally known as EIA Recommended Standard 232. RS232 is one of the oldest serial communication standards with ensured simple connectivity and compatibility across different manufacturers. Originally, the DTEs in RS32 are electromechanical typewriters and DCEs are modems.

Final Deliverable of the Project Hardware SystemCore Industry EducationOther IndustriesCore Technology OthersOther TechnologiesSustainable Development Goals Quality Education, Industry, Innovation and Infrastructure, Responsible Consumption and ProductionRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	68800
HMI	Equipment	1	15000	15000
Acrylic sheet	Equipment	1	5000	5000
Push button	Equipment	4	200	800
Toggle switches	Equipment	2	400	800
Selector Switches	Equipment	1	200	200
Lamps	Equipment	8	700	5600
24 Volts power supply	Equipment	1	5500	5500
Emergency Breaker	Equipment	1	3500	3500
Banana Cables	Equipment	50	20	1000
Miniature Relays	Equipment	4	600	2400
RS-232 Protocol	Equipment	1	5000	5000
Printing	Miscellaneous	1	2000	2000
PLC	Equipment	1	22000	22000