Feasible Interfacing and Programming of Industrial Control Technology Unit with PLC’s and Robots

The International Journal Of Engineering And Science (IJES)
|| Volume || 4 || Issue || 12 || Pages || PP -42-48|| 2015 ||
ISSN (e): 2319 – 1813 ISSN (p): 2319 – 1805
www.theijes.com The IJES Page 42
Feasible Interfacing and Programming of Industrial Control
Technology Unit with PLC’s and Robots
Dr.S.Venkateswarlu1
Professor, C.Rajesh2
Lecturer
(Department of Mechanical Engineering, GPCET,KURNOOL/JNTUA, INDIA)
(Department of Mechanical Engineering, SKIT/JNTUA, INDIA)
--------------------------------------------------------ABSTRACT-----------------------------------------------------------
Industrial control technology unit is a representation of an industrial assembly system that allows the study of
control methods used in product assembly and inspection in a manufacturing process. The Sensors and
actuators are used to sort components, assemble them and test for correct assembly followed by acceptance or
rejection. The unit assembles two components a plastic ring and an aluminum peg can be controlled from a PLC
using the 24v DC I/O interface. Correct programming of the controller must be achieved to ensure scrap
components are not sent to the final assembly area. A programmable logic controller is a digital computer used
for automation of electromechanical processes. ICT unit is interfaced with Robot for work piece transfer. In
present work PLC’S is Interfaced with the 6-axis robot -Pneumatic gripper.
Keywords: Industrial control technology, programming logic controllers.
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Date of Submission: 22 November 2015 Date of Accepted: 13 December 2015
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I. INTRODUCTION
Industrial control system (ICS) is a general term that encompasses several types of control systems used in
industrial production, including supervisory control and data acquisition (SCADA) systems, distributed control
systems (DCS), and other smaller control system configurations such as programmable logic controllers (PLC)
often found in the industrial sectors and critical infrastructures. ICSs are typically used in industries such as
electrical, water, oil, gas and data. Based on data received from remote stations, automated or operator-driven
supervisory commands can be pushed to remote station control devices, which are often referred to as field
devices. Field devices control local operations such as opening and closing valves and breakers, collecting data
from sensor systems [3].
DCS systems generally refer to the particular functional distributed control system design that exist in
industrial process plants (e.g., oil and gas, refining, chemical, pharmaceutical, some food and beverage, water
and wastewater, pulp and paper, utility power, mining, metals). The DCS concept came about from a need to
gather data and control the systems on a large campus in real time on high-bandwidth, low-latency data
networks. It is common for loop controls to extend all the way to the top level controllers in a DCS, as
everything works in real time. These systems evolved from a need to extend pneumatic control systems beyond
just a small cell area of a refinery [4].
. PLC (programmable logic controller) evolved out of a need to replace racks of relays in ladder form.
The latter were not particularly reliable, were difficult to rewire, and were difficult to diagnose. PLC control
tends to be used in very regular, high-speed binary controls, such as controlling a high-speed printing press.
Originally, PLC equipment did not have remote I/O racks, and many couldn't even perform more than
rudimentary analog controls.
The boundaries between these system definitions are blurring as time goes on. The technical limits that
drove the designs of these various systems are no longer as much of an issue. Many PLC platforms can now
perform quite well as a small DCS, using remote I/O and are sufficiently reliable that some SCADA systems
actually manage closed loop control over long distances. With the increasing speed of today's processors, many
DCS products have a full line of PLC-like subsystems that weren't offered when they were initially developed.
The Industrial practitioners and researchers have been dealing with this area to overcome such problems [5-6].

Feasible Interfacing and Programming of Industrial…
II. LITERATURE SURVEY
II.1 Introduction
In early 20th century, microprocessors are used for controlling power distribution among various units of an
industry(Hughes, 2000). The applications of microprocessor suffer from a basic limitation that it fails to alter the
maximum demand level during load fluctuations. This has resulted in development of PLC circuitry to be
incorporated in the place of microprocessor, in order that the demand level can be altered to suit the load
fluctuations resulting in a smooth uninterrupted and continuous power distribution. PLCS are miniature
individual computers, using hardware and software to perform the control functions. [1-2].
The major disadvantages of the controls are, the problem of fixed imaginary values used for comparing and
controlling. PLCS are preferred more for their merit of providing flexible and absolute real values. The first
PLC was traced back to (Hughes, 2000) when Bed Ford Associate developed a device called modular digital
control for general motors. This was used by General Motors to replace the traditional relay based machine
control system. Today’s PLCS are designed not only to communicate with control systems, but also to perform
reporting functions and diagnose the failures. Table1: brings out a comparison between the applications of
microprocessors and PLCS.
Table 1: PLCS in comparison with microprocessor controls
S.no PARTS µC PLC
1. Inputs 3-5 V Higher rating
2. Input condition Non-isolated I/O Isolated I/O
3. programming Complicated easy
4. Environment Affected by noise Can’t affected by noise
5. Outputs
Fast and it may vary because of
disturbance
Rugged outputs
II. 2 Problem Statement
In todays the large and medium scale industries, are frequently hold with vibrations, temperature, humidity, and
noise factors. Microprocessor controllers are well utilized until the PLCs are coming into picture. The biggest
single disadvantage of microcontrollers is speed. If you need a response to an input in less than a few
microseconds, then hardware is pretty much the only way to go. Correcting errors and pre-testing phenomena
are very much reliable need during above mentioned working conditions.
To address above issues a program PLC is proposed in the place of a microprocessor circuitry. PLC is a
controlling device consisting of a programmable processing unit using specialized computer languages.
II. 3 Objective Of The Project
The objectives of this project are to:
i. Build PLC circuit to control valves sequences and counter to move the ICT system.
ii. Integrate PLC with Industrial robot system.
iii. Improve flexibility of existed µC controller system.
iv. Compare the programming easiness with existed Microcontrollers.
III. MATERIALS AND METHODS
III.1 Project Requirement Specification
 Inputs 5 x 24V d.c.
 Outputs 11 x 24V d.c.
 Chain conveyor 24V d.c. Motor with gearbox and
slipping clutch
 Belt conveyor 24V d.c. Motor
 Sensors 3 x Infrared sensors
4 x Inductive Sensors
1 x Capacitive Sensor
1 x Fibre Optic Sensor
 Solenoids 1 x 24V d.c. rotary solenoid
2 x 24V d.c. linear solenoid
 Switched Faults Six switchable faults
 Control 1 x Start and Stop switch in

III.2 Software Requirements
All the software’s that used in this work are as mentioned in the following;
 Siemens S7-200
 Aristocate
Figure 3.1: Software requirements
Figure 3.2: Siemens S7-200 Home Page Figure 3.3: M-Robot Aristo Software main screen
III.3 Programming Methods
Digital computers, being general-purpose programmable devices, were soon applied to control of industrial
processes A PLC is an example of a hardreal-time system since output results must be produced in response to
input conditions within a limited time, otherwise unintended operation will result. Generally the software
provides functions for debugging and troubleshooting the PLC software, for example, by highlighting portions
of the logic to show current status during operation or via simulation. The software will upload and download
the PLC program, for backup and restoration purposes. In some models of programmable controller, the
program is transferred from a personal computer to the PLC through a programming board which writes the
program into a removable chip such as an EEPROM or EPROM.
enclosure
1 x Emergency Stop Switch
 Connection 1 x 15 way D type connector 24v dc
Outputs
1 x 15 way D type connector 24v dc
Inputs
2 x 4mm power terminals
2.1mm power jack socket
 Power supply requirements 24V d.c. @ 2.5A

PLC Program [7-8]:
Here after a ARISTO ROBOT is interfaced with the system for transfer of entity. The program is as follows:
ARISTO-M Robot Program:
SPEED 60
LABEL MTAB
IF_PORT 0 JUMP LOAD
IF_PORT 1 JUMP UNLOAD
JUMP MTAB
LABEL LOAD
PORTMASK 0
JOINT A1 86.51 A2 -86.96 A3 88.34 A4 0.00 A5 -4.64 A6 81.23
GRIPPER OPEN
JOINT A1 86.94 A2 -85.77 A3 85.05 A4 0.00 A5 -10.31 A6 81.23
GRIPPER CLOSE
JOINT A1 86.94 A2 -89.86 A3 89.09 A4 0.00 A5 -10.31 A6 81.23
JOINT A1 0.98 A2 -89.86 A3 89.09 A4 0.00 A5 -10.31 A6 81.23
JOINT A1 -1.47 A2 -87.61 A3 97.84 A4 0.00 A5 -14.59 A6 81.22
JOINT A1 -1.47 A2 -87.61 A3 99.26 A4 0.00 A5 -14.59 A6 81.21
GRIPPER OPEN
JOINT A1 -1.47 A2 -89.55 A3 101.19 A4 0.00 A5 -14.59 A6 81.22

JOINT A1 -1.47 A2 -90.00 A3 89.97 A4 0.00 A5 -14.59 A6 81.22
PORTMASK 1
PORTMASK 0
JUMP MTAB
LABEL UNLOAD
PORTMASK 0
GRIPPER OPEN
JUMP MTAB
Figure 3.3: M-Robot Aristo Software main screen
Finally the work completed on plc programming for assembly operation and ARISTO-M programming
for work piece transfer operation by following fundamentals. Thus, the total industrial control technology unit is
implemented and completed the assembly operation successfully. And also completed the pick and place
operation of work piece from one work station to another work station [9].
Chain conveyors utilize a powered continuous chain arrangement, carrying a series of single pendants. The
chain arrangement is driven by a motor, and the material suspended on the pendants is conveyed. Chain
conveyors are used for moving products down an assembly line and/or around a manufacturing or warehousing
facility.
Figure 3.9: Chain Conveyer-Spring Solenoid-Rotary Solenoid Used In Project

Chain conveyors are primarily used to transport heavy unit loads, e.g. pallets, grid boxes, and industrial
containers. These conveyors can be single or double chain strand in configuration. The load is positioned on the
chains; the friction pulls the load forward. Chain conveyors are generally easy to install and have very minimum
maintenance for users.
Figure 3.9: Front view and Top view
A chain conveyor processes the component through the sort area; the plastic rings and aluminum pegs
proceed down a ring and peg chute and are then assembled on the belt conveyor. At the assembly check area
components are inspected for correct assembly and when the components reach the final area, if correctly
assembled they proceed to the acceptance area, faulty assemblies are rejected into a reject bin. Correct
programming of the controller (PLC or PC) must be achieved to ensure scrap components are not sent to the
final assembly area. Industrial control technology unit is interfaced with Robot for work piece transfer. In
present work PLC’S is Interfaced with the 6-axis robot and programmed for pick and place operation using
Pneumatic gripper [10].
IV. CONCLUSION
New technological advancements and current market and product domain conditions require new
engineering design approaches to be applied, so that multi-functional, complex and reliable products in reduced
time to satisfy market requirements can be designed and developed. This requires mechatronics design and
eventually mechatronics education to be applied in real life and become a reality.
 The implementation of the PLC in industrial control technologies, proves to be one of the important
controllers in industries for its simplicity and robustness and is used all over the world.
 PLC’s are very good for controlling outputs based on the inputs. They are amazingly robust and are
able to withstand all sorts of difficult conditions such as extreme temperature or dust in the air. They
even last for a very long period. They don’t have contacts that wear out, like relays do. They also can
switch fairly quick without much heating in direct contrast to relays.
 For any application we need not to change the whole structure only different program has to be
embedded as like any other programmable devices. Compared to relays PLCs are almost always a
better choice.
 Today the PLC’s are used for control & automation job in a single machine & it increases up to full
automation of manufacturing / testing process in a factory.
 The interfaced 6-axis robot is more efficient than existing models for pick and place operation.
On the downside it could be observed that PLCs are not very good at handling large amount of data, or
complex data. Lack of standardization is also one of the major disadvantage of the PLC. This causes much
confusion if the PLC used for an application is replaced by one from a different manufacturer, or if a PLC
programmer is replaced by a person with a different understanding of PLC programming.
REFERENCES
Journal Papers:
[1] Ho JM, Juang FC, A practical PWM inverter control circuitry for induction heating and
studying of the performances under load variations, Industrial Electronics Proceedings, IEEE
International Symposium on , 7-10 Jul 1998, 1:294-299
[2] Kwon Y, Yoo S, Hyun D, Half-bridge series resonant inverter for induction heating
applications with load-adaptive PFM control strategy, Applied Power Electronics Conference And Exposition,
14-18 Mar 1999; 1:575 -581,

Books:
[3] L. A. Bryan, E. A. Bryan, Programmable controllers: theory and Implementation 2nd ed.,ISBN 0-944107-
32-X, (Industrial Text Company, 1997).
[4] S. K. Bhattacharya and Brijinder Singh, Control of electrical machines
[5] M. H. Rashid, Power Electronics: Circuits, Devices and Applications 2nd Ed, (Prentice-Halllnc., 1993).
[6] W. Bolton, Programmable Logic Controllers Fourth Edition, ISBN-10: 0-7506-8112-8,
(Elsevier Newnes, 2006).
[7] Programmable Logic Controllers Programming methods and applications-Prentice Hall
[8] Programmable Logic Controllers (PLCs) © 2002 Keyence Corporation.
Theses:
[9] Onur Alper Erdener, Development Of A Mechatronics Education Desk , master of science, the graduate
school of natural and applied sciences of the middle east technical university, dec-2003.
Proceedings Papers:
[10] Espi JM, Navarro AE, Maicas J, Ejea J, Casans S, Control circuit design of the L-LC
resonant inverter for induction heating, IEEE Power Electronics Specialists Conference, 2000, 3: 1430-5
Biographies and Photographs
Dr.S.Venkateswarlu was born on 10th
may 1970. He is currently working as Professor in
Mechanical Engineering Department of G.Pullaiah College of Engineering and Technology,
Kurnool ( A.P ). He has more than 20 years of Teaching experience. He received his B.Tech in
Mechanical Engineering from SRI VENKATESWARA UNIVERSITY, Tirupathi (A.P) in 1992.
He has done M.Tech from P.S.G.COLLEGE OF TECHNOLGY, Coimbatore in 1995 and
completed his Ph.D from SRI VENKATESWARA UNIVERSITY, Tirupathi (A.P) in 2014.
Chittam Rajesh was born in 25th Sep 1988. He is currently working as a Lecturer in Mechanical
Engineering Department of Sri kalahasteeswara Institute of Technology, Srikalahasthi (A.P). He
has 3 years’ experience in teaching, one year industry. He received his B.Tech in Mechanical
Engineering from Jawaharlal Nehru Technological University, Anantapur (A.P.) in 2009. He has
done M.Tech from SRI VENKATESWARA UNIVERSITY, Tirupathi (A.P) in 2012 and
planning for Research programme. His research interests are Advanced machining, Manufacturing
technologies and Industrial technologies.
.

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