Industrial Monitoring System Using PLC
To design this project, we will use PLC and WPLSoft software to analyze our code on online simulator. Further we will implement this project on hardware. In this protype the product or object will be detected by Infrared sensor and will be picked by first robotic arm. The object will move on
2025-06-28 16:33:07 - Adil Khan
Industrial Monitoring System Using PLC
Project Area of Specialization Electrical/Electronic EngineeringProject Summary- The proposed SDP is “Industrial Monitoring system using PLC” which lies in the field of control. Originally the tiresome tasks in industries involved immense human labor but today industries are focusing on automated optimized machines.
- “In this project we will design an automatic Pick and Place system for an industry which will be controlled and monitored using Programmable Logic controller (PLC).” PLC plays a lead role in the world of automation. PLC is reliable and hence provides accurate output. Here we are going to make the pick and place operation fully automatic with the help of PLC, conveyor belts and robotic arms.
- The proposed prototype will increase the speed of the process making it more productive and hence efficient.
- To study about industrial monitoring and control system using PLC.
- To develop an algorithm which will allow the robotic arm to grasp objects of different shapes and sizes.
- To design and implement a prototype of Pick and Place system for an industry.
To design this project, we will use PLC and WPLSoft software to analyze our code on online simulator. Further we will implement this project on hardware. In this protype the product or object will be detected by Infrared sensor and will be picked by first robotic arm. The object will move on the conveyor belt where its location can be detected by proximity sensors. Then the object will be picked by second arm and that will place it on the next stage of production. The whole process will be monitored and controlled using PLC. For PLC programming we will use ladder logic. The logic can be changed without much alteration in electrical setup. Human Machine Interface (HMI) will be used if required. HMI will work as alarm or any indication device during the operation in case of any emergency or failure. While designing and implementing the prototype we will take great care of logic design for the system, choice of right equipment and programming of PLC. The block diagram of the process in shown in Figure.
- Pick and Place automation systems are widely used in the industrial processes as a section of a complete assembly system. Our project has vast application in the manufacturing industries as the picking and placing of objects and products are very common there. Moreover, the project can be implemented in cement industries, Pharmaceutical industries and in large scale industries for automatic picking and placing. The proposed project will increase the speed and efficiency of the process of picking and placing so it will increase the productivity which is need of hour. The design will be less costly, more reliable, efficient, and simple. As it is fully automated system so it will eliminate the human interference so is the human errors.
- The major problem faced in automation is the inability of system to detect uncertain and unprecise positioning which may cause misplacing, damaging or any sort of undesired outcomes from the machine. The suggested program helps us to, not only detect any object in the machine’s vicinity but also to pick and place correctly in its desired position and return the objects to their starting positions in any situation of machine or power failure.
In this setup when the power supply is ON, first an object is detected through IR sensor and if its output is ‘true’, PLC gives output signal to robotic arm 1 which again uses IR sensor to trace the pin-point location of object to be picked and then, places the object on the conveyor belt. Then proximity sensor senses the object and objects starts travelling on the conveyor belt. Then this object is picked by another robotic arm from where it is shifted to the next stage of operation. It is a time-based process because it is crucial to know the time difference between the movement of two objects. The whole operation is monitored and controlled using PLC. As PLC is more reliable, it makes the operation more efficient.
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 66500 | |||
| Programmable Logic Controller | Equipment | 1 | 30000 | 30000 |
| Conveyor belt System including motor | Equipment | 1 | 12000 | 12000 |
| Robotic Arms | Equipment | 2 | 9000 | 18000 |
| IR sensors | Equipment | 1 | 750 | 750 |
| Proximity sensor | Equipment | 1 | 750 | 750 |
| Cables, indicators, relay switches, and harware requirements etc. | Miscellaneous | 1 | 5000 | 5000 |