Multifunctional Automatic Industrial Drives Learning Trainer Using PLC, HMI, VFD

Project Title

Multifunctional Automatic Industrial Drives Learning Trainer Using PLC, HMI, VFD

Project Area of Specialization Electrical/Electronic EngineeringProject Summary

Aim of this study is to resolve the automation and control issues in Pakistani University or industry with low cost control and effective data analysis for industrial automation. The objective of study is to take the overview of industrial automation need for present Industries requirement with advance communication facility, record generation for report analysis as well as visualization of information & utilization of VFD function to reduce the use of mechanical system and optimize the energy for manufacturing & increase the operation flexibility. 

Project Objectives

The main aim of this study is to design and development of PLC training module for positioning and sorting. At this stage basic there is important to recognize the scope of study. The scope consists three main section stated below: The scope of the study is:

A ) Student will not involve in hardware development but focusing on integration between controller and input/output, setup, and construct a PLC logic programming using prototype develop in the study.

B ) Student understanding in the knowledge, comparison between existing approach (Teacher Centred Learning) and Student Centred Learning approach based on achievement in technical knowledge (problem solving skill – quality and timing) and soft skill ( team work and presentation skill).

C ) conduct a questionnaire survey to identify the effectiveness and deficiencies of the both approach and the developed prototype.

Project Implementation Method

We present Consumer product manufacturers increasingly rely on the cooperative development of multi-disciplinary technical systems that often span the electrical, mechanical, and industrial engineering domains. Design and production engineers are frequently organized into cross-functional teams in which members bring critical skills to the assembled group (Wagner, 1999). To facilitate multi-disciplinary teams, engineers must develop their teamwork, problem solving, synergistic design, and communication skills as well as the traditional technical competencies (Slivovsky et al., 2003; Simpson et al., 2001). Further, it is increasingly presumed that competitive engineering graduates will have these skill sets in place and be able to contribute immediately to their assigned teams (Steiner, 2004). In essence, the expanding 7 implementation of sensors, actuators, and digital control across all engineering systems suggest that students need a mechatronic systems perspective (Grimheden and Hanson, 2001) with an opportunity to develop leadership, communication, and interpersonal skills. The availability of mechatronic courses within the engineering curriculum can help prepare students for the global workplace. In order to make this happen, the study for design and development of PLC training module for positioning and sorting are importance. In this training module, student will be able to:-

a) Learn the basic operation of positioning and sorting.

b) Structure of input and output (switches button and components) and their address.

c) Identify the positioning and sorting components on PLC training module.

d) Describe the function of PLC logic programing such as position and timer function.

e) Design a ladder diagram and function block diagram program structure and learn how to program then minimize the program language to be a simple network program.

Benefits of the Project

Future automation engineers will no longer be limited to the field of production. Many automation projects, for example will be implemented within the so-called smart environment. In transportation, buildings, and health care, future automation projects will have closer proximity to people’s everyday lives. The engineers’ expertise in automation will be applied in many non-traditional fields. These innovations will drastically change people’s lives, adding convenience. The automation systems will become an important foundation for the future construction and operation of intellectualized and automated societies.

This autonomic network concept can benefit the productivity of smart applications in smart environment. This work will also facilitate to investigate the new strategies to improve the security management in automation field.

Technical Details of Final Deliverable

This study considered Delta make compact PLC which is having on board display , digital 8 input and 8 output of 24v dc and 1 expansion module having 4 channel analog output 0-10 v . For programming of PLC DOPsoft & WPLSoft is used as a programming platform and Designing Platform to develop the logic, testing and simulation. This study has considered the exor HMI (human machine interface) of 7 inches touch screen having communication cable for interfacing of the base PLC. This is used for information exchange between the system and the human. All the basic parameters like voltage, current, power, power factor, and frequency can be monitored through using rs -485 communication protocol to the HMI (human machine interface) or PLC (programmable logic controller). The data registers of respective parameters can be read directly. This study has used VFD (variable frequency drive), omron make VFD (variable frequency drive) to control the speed of induction motor. We can vary the speed of the induction motor from 0 to 100 % of motor rated rpm. Can change the direction and speed locally or remotely through HMI (human machine interface) and PLC (programmable logic controller). This study work can provide the accurate protection to the motor by reading the parameter from multifunction meter.

Final Deliverable of the Project Hardware SystemCore Industry EducationOther Industries Energy , Manufacturing Core Technology Clean TechOther Technologies Internet of Things (IoT), Shared Economy, Clean TechSustainable Development Goals Quality Education, Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Responsible Consumption and ProductionRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	64118
Steel Panel 24*28 inch	Equipment	1	5000	5000
Delta PLC + HMI	Equipment	1	37000	37000
VFD (Omron Mini vs)	Equipment	1	5000	5000
Limit Switch	Equipment	1	100	100
Proximity Sensor	Equipment	1	550	550
PT 100 Sensor	Equipment	1	750	750
Power Supply 24 VDC	Equipment	1	1000	1000
connector	Miscellaneous	6	200	1200
Emergency Button	Equipment	1	400	400
Indication led	Equipment	1	250	250
buzzer	Equipment	1	100	100
A/M Meter	Equipment	1	500	500
Smart Network Device	Equipment	1	9500	9500
Win Pin	Miscellaneous	10	80	800
Relay 24 v	Equipment	2	370	740
T-P 3PIN	Miscellaneous	11	18	198
Communication Cable	Miscellaneous	1	400	400
Power Cable lead	Miscellaneous	1	200	200
Cable tie	Miscellaneous	1	250	250
Nut Bolts	Miscellaneous	12	15	180