Design and Fabrication of PLC based Industrial Trainer
Programmable Logic Controller (PLC) is a necessity and demand of every running commercial and industrial facility for automation in the fields of automobiles, cement industries, steel industries, and fertilizer industries. In addition, general-purpose PLCs are also common controllers utilized in the
2025-06-28 16:31:38 - Adil Khan
Design and Fabrication of PLC based Industrial Trainer
Project Area of Specialization RoboticsProject SummaryProgrammable Logic Controller (PLC) is a necessity and demand of every running commercial and industrial facility for automation in the fields of automobiles, cement industries, steel industries, and fertilizer industries. In addition, general-purpose PLCs are also common controllers utilized in the control of powerplants and industrial plants which depend on four fundamental variables during the process: pressure, temperature, motion, and leveling.
Nowadays, industries are producing a lot of PLC based automation jobs, but our students are only equipped with the skills of Arduino and Raspberry PI controller which creates a gap between industry’s demand and students’ capacity to supply. So, whenever students get a chance to work in any automation industry, it is likely that they get interaction with PLCs and the consequence is that they face some difficulties in using controller due to lack of basic knowledge.
The solution to this problem can be tackled by designing a basic industrial trainer which examines the procedure of controlling the two industrial processes; the mixture of different liquids and second is multi-sorting of two different objects (metal and wood ) in two different sizes (small and large). The above two processes are controlled by PLC, in which programming of these processes are already sorted in and we can make the changes as per the program in the WPL software which is used for the PLC programming. Human Machine Interfaces (HMI) can be used to control the PLC database. The whole process can be controlled and monitored graphically. HMI is also programmed through DOP software like PLC where its programming is based on WPL software.
The objective of this project is to develop a PLC based Industrial Trainer to enhance the hands-on skills in laboratory exercises through electrical wiring, assembly of industrial control components, interfacing of HMI, and network.
The methods of the first process, the mixture of different liquids, is used in the Toothpaste manufacturing industry, cold drink companies and other chemical industries and the second process, object sorting technique, is utilized in bricks and grain industries.
Project Objectives- To develop a PLC based Industrial Trainer for students and workers.
- To enhance the teaching and learning process for PLC-based systems.
- To make the replica of Industrial processes for practicing.
- To identify and select the industrial control components.
- To fabricate(contrive) and assembly of structure and components.
- To control the fundamental process variables: pressure, temperature, level, and motion.
- To interface PLC and HMI.
The design and fabrication of PLC based industrial trainer is based on the two industrial processes, which are being controlled by PLC and HMI.
Figure(3) shows the synergetic combination of two industrial processes via PLC and HMI
MIXTURE PROCESS
When the mixture process starts, solenoid A and B energize. This permits the two liquids to begin filling the tank. When the tank is filled to desired weight sensed by the load cell, the sensor and plc gives input signal to the solenoids A and B that will be de-energized and starts the motor to mix the two liquids The motor is permitted to run until the required temperature is sensed by the temperature sensor to stop the motor and solenoid C energizes to drain the tank. When the tank is empty, the level switch de-energizes solenoid C. An emergency STOP button can be used to stop the process at any point. If the motor becomes overloaded, the action of the entire circuit will stop. Once the circuit has been energized, it will continue to operate until the required cycles are to be completed.
Figure(1) shows the flow diagram of this process.
SORTING PROCESS
The object will be placed on the conveyor. Then the proximity sensor will sense the object that starts the conveyor belt and the object will be transported from source to target. During its travel, the sensor will sense the type of material like metal and wood. The signal will be then given to the plc, so according to the signal, the corresponding pushing mechanism will be activated for large and small objects that will be pushed out from the conveyor belt. The sensor and PLC will give input to pushing mechanism to activate respectively as per the size of component i.e. small and large size of the component if the size of the component is small pushing mechanism 1 will be activated and if the size is large then pushing mechanism 2 will be activated. After this activation of the pushing mechanism, the small and large component will go to the basket placed right and left side of the machine. After the sorting of the object, the conveyor belt will be automatically switched off
Figure(2) shows the flow diagram of this process.
- Industrial trainer is beneficial for students and industrial workers for learning and practicing PLC-based automation.
- It helps to achieve the gap between of the automation industry and students.
- PLC based industrial trainer helps students to execute programming a PLC in Process and Manufacturing industries.
- It helps the students in getting recruited in the best industries with job stability and proper salary.
- The PLC trainer is a very useful tool for learning PLC hardware, software and programming on one’s own.
- Automated liquid mixing:
The Automated liquid mixer performs the mixing of two different liquids in predetermined proportions. When reservoir tank-A and tank-B transferring the respective liquids for 5 seconds to the overhead mixing tank. The overhead mixing tank connected with the load cell when load cell show the desired weight it send signal to PLC to start the mixing process with the starting of the process temperature sensor start to sense temperature and with that heater will also start when the desired temperature will sense by the sensor it stop the motor and solenoid valve open for 10 seconds to fluid flow out. The Overhead Mixing Tank contains sensors to sense the liquid level i.e. low level, high level, and the emergency level. The output of the Emergency Level Sensor is connected to the Emergency Alarm Sub-system. The PLC generates an emergency alarm output whenever the level in the overhead tank exceeds the high level. This additional safety has been incorporated to ensure that the automated system works safely even in the case of failure of the high-level sensor.
2) Object sorting mechanism:
The final product of the purposed system will be able to detect the object with the help of sensors that are controlled by the PLC. Once objects placed on the conveyer belt, proximity sensors i.e. inductive sensors, capacitive sensors, and photoelectric sensors detect the article and differentiate among the construction material of the object (metal and wood). As the material is recognized, the object is then identified by the distance sensors placed on the different heights (small and large). Moreover, the object is sorted in the specific box through PLC which controls the position of pneumatic cylinders and the purpose of DC gear motor is to control the speed of the conveyer belt.
The whole above two processes are controlled by PLC which is having the program and we can make the changes as per the program in the WPL software which is used for the PLC programming. The human-machine interface (HMI) interface can also implement. The whole process can be controlled and monitored graphically. HMI software like DOP can be employed with PLC.
Final Deliverable of the Project HW/SW integrated systemCore Industry EducationOther Industries Petroleum , Food , Manufacturing Core Technology RoboticsOther Technologies OthersSustainable 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) | 78000 | |||
| PLC | Equipment | 1 | 30000 | 30000 |
| HMI | Equipment | 1 | 15000 | 15000 |
| Load cell module | Equipment | 1 | 2000 | 2000 |
| Load cell | Equipment | 1 | 2000 | 2000 |
| Temperature sensor | Equipment | 1 | 1200 | 1200 |
| Level sensor | Equipment | 1 | 1500 | 1500 |
| Pressure switch | Equipment | 1 | 1200 | 1200 |
| Heater | Equipment | 1 | 1200 | 1200 |
| Power supply | Equipment | 1 | 2700 | 2700 |
| Proximity Sensor | Equipment | 1 | 1500 | 1500 |
| Inductive Sensor | Equipment | 1 | 1300 | 1300 |
| Capacitive Sensor | Equipment | 1 | 1500 | 1500 |
| Distance Sensor (size measurement) | Equipment | 1 | 2000 | 2000 |
| Discharge sensor (count objects) | Equipment | 3 | 1200 | 3600 |
| Cam sensor (inductive) | Equipment | 1 | 1300 | 1300 |
| Frame | Miscellaneous | 1 | 5000 | 5000 |
| Conveyor belt | Miscellaneous | 1 | 2000 | 2000 |
| 5/2 control valve | Miscellaneous | 4 | 500 | 2000 |
| Miscellaneous | Miscellaneous | 1 | 1000 | 1000 |