PLC Based Automation of Industrial Proses with HMI
The role of a Programmable Logic Controller (PLC) in industrial automation. Programmable Controllers are similar to industrial computers PLCs are used in industrial automation to increase reliability, system stability and performance, minimizing the
2025-06-28 16:34:29 - Adil Khan
PLC Based Automation of Industrial Proses with HMI
Project Area of Specialization Electrical/Electronic EngineeringProject SummaryThe role of a Programmable Logic Controller (PLC) in industrial automation. Programmable Controllers are similar to industrial computers PLCs are used in industrial automation to increase reliability, system stability and performance, minimizing the need for human operators and the chances of human error. This project is industrial automation by using PLC and display HMI. This Project automation purpose for use only one PLC but control many sensors. For Example: Temperature Sensor: Temperature sensor sense the value of temperature and send the PLC input I/O then PLC control the motor speed (normal temperature normal speed of motor and high temperature high speed motor). The speed control induction motor by using VFD. Then display the HMI.Temperature Sensor: Temperature sensor sense the value of temperature and send the PLC input I/O then PLC control the flow of fueled (low temperature full flow of fueled and high temperature low/full flow of fueled). The flow of fueled control by using flow meter. Then display the HMI. Pressures Sensor: Pressure sensor sense the value of pressure and send the PLC input I/O then PLC control the flow of Air (low Pressure low flow of air and high-Pressure high flow of air). The flow of air control differential pressures sensor. Then display the HMI. Level Sensor: Level Sensor sense the level of water and send the PLC input I/O then PLC control Level of water (low level increase the level of water and high level decrease the level of water). The maintain the level of water by using point level conductivity sensor. Then display the HMI
Project ObjectivesIndustrial automation of production processes enhances labor efficiency and allows cutting net cost and improving product equality moreover it extends the equipment service life save consumables and raw materials and improves production safety as a whole improve production control. The industrial automation uses different sensor.
For Example:
Temperature Sensor: This sensor use textiles industry’s before dyes the fabric wash the hot water (water temperate less then boiling point). Maintain water temperature by using temperature sensor. Sensor sense the temperature of water and send signal to PLC then PLC operate burner for Lower temperature and off maximum temperature.
Level Sensor: This sensor uses industry automation for water tank storage. The level sensor maintains the water level of tank. The sensor normally operates the lower level and maximum level of water in tank. Thread working is that it worms when water is very low and increase upper level.
Pressure Sensor: This Season Use Industrial automation for industry machines operate. Industrial Machine operate not only 3 Phase Supply. We also supply fix Pressure. It also maintains the fix pressure
Project Implementation MethodIn today we use automation in industries. Automation process the work automatically. Industrial automation is the use of control systems and handling different processes and machineries in an industry to replace a human being.
Water level: In industry there are use water tank. We use water level for mention the water level in tank. When water was very low in tank the sensor turns on the pump and refill the water when water increasing up then it shows worming and open the duck to decrease the water.Water level indicators work by using sensor probes to indicate water levels in a storage tank. As mentioned above, the control panel can be programmed to automatically turn on your pump to refill the water again.
Pressure sensor: In industry some machines also require pressure for starting we also use pressure slander to provide the fix pressure for machines in this case the machines start and run. When pressure no provide to machine it not start and run in only 3 phase supply.
Temperatures sensor: Some work of industry depends on hot water we use temperatures sensor to maintain the water temperature. When water is normally hot the temperature sensor hot the water on depending level. When the water is very hot then temperatures sensor low the burning level and mention the water
In industrial power plant some time it temperature also very Hight we also attach the temperature sensor in power plant when temperature of power plant high the temperature sensor also turn on the water pump the water cercolate in power plant radiater and cool it
Benefits of the ProjectAutomation is to control the industrial machinery and process with plc (Programable logic Controller) It helps reduce the need for human intervention. Automation and Control system enable safe and efficient operation of Industrial Plants by minimizing risks. This automation based on programable logic controller (PLC) and display the Human machine interface (HMI). Most sensitive sensor used for Pressure Sensor, Temperature Sensor and Level Sensor.
- With PLC is very reliable from another control system in industry environment.
- Try to minimize Time, Place and Manpower.
- This process must be improved and new step for industry automation.
- Lower consumption of human.
- The system is easy to operate.
- It reduces the time of industrial process.
- All automation prosses show 2D in HMI.
This project easily controls industrial process without any human mistakes. The all process control automatically by using PLC. Industrial water tank already maintain lower level and maximum level of water. We add work in this industrial tank when the water level before is very low and increase upper level then sensor worn and sometime water level increase upper then axillary vale open. In Textile industry water temperature level maintain automatically in washing proses. We provide constant pressure according to required industrial machineries. We maintain temperature automatically of industrial power plant.
Final Deliverable of the Project HW/SW integrated systemCore Industry ManufacturingOther IndustriesCore Technology Augmented & Virtual RealityOther TechnologiesSustainable Development Goals Industry, Innovation and InfrastructureRequired Resources| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 77900 | |||
| PLC (Programmable Logic Controller) | Equipment | 1 | 20000 | 20000 |
| PLC ADC (Analog to Digital Convertor) | Equipment | 1 | 5000 | 5000 |
| HMI (Human Machine Interface) | Equipment | 1 | 11000 | 11000 |
| VFD (Variable Frequency Devise) | Equipment | 1 | 3500 | 3500 |
| Temperature Sensor | Equipment | 2 | 4000 | 8000 |
| Pressure Sensor | Equipment | 1 | 4000 | 4000 |
| Level Sensor | Equipment | 1 | 2000 | 2000 |
| Copper Tube's | Equipment | 1 | 1400 | 1400 |
| Air Compressor | Equipment | 1 | 3500 | 3500 |
| Three Phase Induction Motor | Equipment | 1 | 4000 | 4000 |
| Relay's | Equipment | 1 | 1500 | 1500 |
| Wire | Equipment | 1 | 1000 | 1000 |
| Project Model | Equipment | 1 | 5000 | 5000 |
| Any Equipment | Miscellaneous | 1 | 8000 | 8000 |