Industrial Automation Processes using PLC
Due to the comprehensive development in the industries, efficiency is necessary. In most of the industries placement of objects i.e. picking and dropping of the object from and to the desired location is quite a task. It is usually done through manual means and is not as efficient as an automated sy
2025-06-28 16:33:06 - Adil Khan
Industrial Automation Processes using PLC
Project Area of Specialization RoboticsProject SummaryDue to the comprehensive development in the industries, efficiency is necessary. In most of the industries placement of objects i.e. picking and dropping of the object from and to the desired location is quite a task. It is usually done through manual means and is not as efficient as an automated system.
To assist this matter, our project sets out to cover not only horizontal or vertical horizons but all three axes efficiently and effectively with a mere touch on the HMI. As far as the reliability of the project is concerned, all the equipment used is of industrial scale and the crane responds to the pick and drop points very precisely (error chance is almost zero).
An electronic prototype (13ft long, 6ft wide and 5ft tall) is designed to demonstrate the behaviour of our idea. The system involved consists of both Mechanical and Electronic Units. The whole crane first moves along z axis to reach the pickup point, then it automatically moves along the y axis to pick up the required object. Finally, it moves along x-axis to reach the drop point. In this way all the three axes are covered.
As a result not only precise movement was achieved rather the whole system was automated.
Project ObjectivesThr project objectives include :
1. Designing of 3 dimensional Gantry Crane in AutoCad.
2. Automation of Crane movement using PLC.
3. Interfacing of various sensors with PLC.
4. Interfacing HMI with PLC for Grapic User Interface.
Project Implementation MethodThe methodology involves:
1. Designing of crane
2. Controlling of motors through PLC
3. Interfacing of Sensors with PLC for controlled movement of motors.
4. Interfacing of HMI with PLC for graphical observation.
5. Desigining of panel.
For designing purpose the software used was AutoCad where assembly was designed. The lengths were chosen according to the hoist that was initailly purchased.
After the designing procedure, PLC was introduced in the project to turn the motors on and off according to our requirement. App
roximity sensors were involved in the project to start and stop the motor according to our desired requirement. Actually, when no input is provided to the sensor, zero bit is provided by the sensor to the PLC. As the hoist of the project or lower steel rods reach their limit where proximity sensors are attached, their value is turned to 1 and hence that part is stopped. Further to provide a graphical user interface, a Human Machine Interface is used where graphics are introduced to make it easy to control the crane by a simple touch. At the end, a simple panel was designed where relays, HMI and PLC is mounted.
The benefits of the project are :
1. Complete automated performance of the crane.
2. Highly precise movement.
3. Touch and Control assembly.
4. Extremely efficient.
5. Real Time Simulation
6. Replaceable in the industry.
The project has enough potential to overcome the manual systems in the current industry since it is built keeping in view the industrial standards. It is very less prone to fault or any sort of unlikely behaviour due to the utilization of latest and modern technology. Further, it eases the persons work by a mere touch on the screen of HMI. where u can control as well as monitor the over all movement.
Technical Details of Final DeliverableThe final demonstration will show, fully automated movement of the crane which will pick and drop weight upto 125kg by a simple touch on the HMI screen.There will be 4 pick and drop points with in the area of the structure. One will be able to select one of the 4 points to pick the desired object and place it to the drop point automatically. In addition one will also be able to observe the current status of the crane on the HMI screen.
Final Deliverable of the Project HW/SW integrated systemType of Industry Transportation Technologies RoboticsSustainable Development Goals Industry, Innovation and InfrastructureRequired Resources| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 80000 | |||
| Weitek HMI | Equipment | 1 | 14800 | 14800 |
| Siemens PLC 1212C | Equipment | 1 | 27000 | 27000 |
| Siemens DC Supply | Equipment | 1 | 1000 | 1000 |
| Proximity Sensors | Equipment | 5 | 400 | 2000 |
| Hoist | Equipment | 1 | 7000 | 7000 |
| Capacitor | Equipment | 2 | 50 | 100 |
| Encoder | Equipment | 1 | 6000 | 6000 |
| Wire 3/29 | Equipment | 1 | 300 | 300 |
| Circuit Breaker | Equipment | 1 | 252 | 252 |
| Electric Motors | Equipment | 4 | 2000 | 8000 |
| Railing tyres | Equipment | 4 | 887 | 3548 |
| Paint | Miscellaneous | 1 | 2000 | 2000 |
| Transport | Miscellaneous | 1 | 3000 | 3000 |
| Fabrication of Prototype | Miscellaneous | 1 | 5000 | 5000 |