Design of Signal Process Multiplexer for PLC

Project Title

Design of Signal Process Multiplexer for PLC

Project Area of Specialization Electrical/Electronic EngineeringProject Summary

Due to the limited number of I/O pins in PLC, the proposed way to interface multiple sensors is using multiplexer as with the help of multiplexer any number of sensors can be connected with PLC. Our project is mainly based on the design of a multiplexer for Programmable Logic Controller (PLC) and interfacing multiple temperature sensors with PLC via that designed multiplexer. SCADA is used for continuous visual monitoring of these temperature sensors outputs given to a PLC via Analog to Digital Converter (ADC). Additionally, the Round-Robin technique is implemented for reading different inputs depending upon our own set priority.

In many fields of scientific research and production practice, temperature monitoring and control is one of the major topics in the discussion on pathways towards a future sustainable developmental society. So advanced measurement and monitoring system is required for measuring the temperature at different points and have decisions based on their mean values. Further, the digital and analog actuators will be controlled based upon the sensor values and control decisions. It is expected to contribute both to the reduction of cost, error reduction, and monitoring parameters stability rather than manual.    

Project Objectives

1. Designing Process Signal Multiplexer for PLC.

2. Interfacing multiple temperature sensors to PLC through the multiplexer.

3. Developing an HMI system to monitor data in real-time.

4. Implementation of Round Robin technique and different frequencies could be selected on run time.

Project Implementation Method

After studying different research papers and analyses of their implementation methods, we organize our project implementation into two parts:

Software Implementation:-

In this step, we design our model on Proteus and PLC software Winproladder for simulation, Proteus for PCB designing, and Easybuilder pro for HMI implementation.

Hardware Implementation:- 

•  Assembling components on PCB.
•  Making a connection of sensors with PLC using ADC module.

Methodology:

• Initializing timer’s pre-set values in PLC.
• Toggle output pins Y0, Y1 and Y2 with respect to their frequency.
• Obtaining output of Decoder IC on the basis of these outputs.
• Trigger relays with respect to output of Decoder IC.
• Getting Temperature sensors data in PLC through ADC.
• Moving sensor data to specific register, labeling respective sensor.
• Displaying data on HMI (Human Machine Interface).

Benefits of the Project

• Exceptionally useful for a wide range of ventures to dissect and observing information from more no. of information sources.
• More feasible for large scale industrial processes.
• Flexible for the changes in various parameters such as temperature.
• Energy and cost consumption will be minimized.

Technical Details of Final Deliverable

The technical view of our project is described below in the form of block view:-

As the figure shows, there are 8 inputs in the multiplexer. These inputs will be turned on sequentially depending upon the bit logic generated by the PLC and are decoded using decoder IC. According to these logics, data of each input will be shown on HMI(Human Machine Interface).

PCB Layout Of Circuit:

Final Deliverable of the Project HW/SW integrated systemCore Industry ManufacturingOther Industries Energy Core Technology RoboticsOther Technologies Internet of Things (IoT)Sustainable Development Goals Decent Work and Economic Growth, Industry, Innovation and InfrastructureRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	44800
PLC	Equipment	1	20000	20000
ADC Module	Equipment	1	16000	16000
Relays	Equipment	8	75	600
Temperature Sensor	Equipment	8	700	5600
Electronic Components	Miscellaneous	50	20	1000
Connectors	Miscellaneous	20	20	400
PCB	Equipment	1	1000	1000
Actuators	Equipment	10	20	200