Industrial Computing - Technology

Programmable logic controller (PLC)

PLC is a digital computer design for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact.

The major components of PLC are power supply, I/O module, processor and programming device.

PLC used in our project is MicroLogix 1400.

The PLC is used in various applications like Car parking control, Materials handling, Machine tools, and Conveyor system.

Arduino UNO

Arduino Uno is a microcontroller board based on 8-bit ATmega328P microcontroller.

Along with ATmega328P, it consists other components such as crystal oscillator, serial communication, voltage regulator, etc. to support the microcontroller. Arduino Uno has 14 digital input/output pins (out of which 6 can be used as PWM outputs), 6 analog input pins, a USB connection, A Power barrel jack, an ICSP header and a reset button.

Use of Arduino Board

The 14 digital input/output pins can be used as input or output pins by using pinMode(), digitalRead() and digitalWrite() functions in arduino programming.

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Each pin operate at 5V and can provide or receive a maximum of 40mA current, and has an internal pull- up resistor of 20-50 KOhms which are disconnected by default. Out of these 14 pins, some pins have specific functions as listed below:

• Serial Pins 0 (Rx) and 1 (Tx): Rx and Tx pins are used to receive and transmit TTL serial data. They are connected with the corresponding ATmega328P USB to TTL serial chip.
• External Interrupt Pins 2 and 3: These pins can be configured to trigger an interrupt on a low value, a rising or falling edge, or a change in value.
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• PWM Pins 3, 5, 6, 9 and 11: These pins provide an 8-bit PWM output by using analog Write() function.
• SPI Pins 10 (SS), 11 (MOSI), 12 (MISO) and 13 (SCK): These pins are used for SPI communication.
• In-built LED Pin 13: This pin is connected with an built-in LED, when pin 13 is HIGH - LED is on and when pin 13 is LOW, its off.

Along with 14 Digital pins, there are 6 analog input pins, each of which provide 10 bits of resolution, i.e. 1024 different values. They measure from 0 to 5 volts but this limit can be increased by using AREF pin with analog Reference () function.

Analog pin 4 (SDA) and pin 5 (SCA) also used for TWI communication using Wire library.

Arduino Uno has a couple of other pins as explained below:

AREF: Used to provide reference voltage for analog inputs with analog Reference () function.

Reset Pin: Making this pin LOW, resets the microcontroller.

Power supply

The Power supply for a Programmable Logic Controller converts the input source power into voltages required for internal circuitry. In some cases, it also provides an isolated VDC supply to power DC input circuits, switches and other indicators. The Power Supply of the PLC is an essential component to running the PLC.

Programmable Logic Controllers are available with operating voltages from 12V to 240V AC or DC, and I/O's up to 512.

Infrared sensor

IR sensor is used to detect objects and obstacles in front of sensor. Sensor keeps transmitting infrared light and when any object comes near, it is detected by sensor by monitoring the reflected light from the object.

It can be used in robots for obstacles avoidance and line follower robot, for security alarm systems, or contactless tachometer by measuring rpm of rotation objects like fan blades.

Detection range is 20 cm and Power supply is 5V DC

Colour sensor

The colour sensor detects the colour of the surface, usually in the RGB scale. Colour is the result of interaction between a light source, an object and an observer.

In case of reflected light, light falling on an object will be reflected or absorbed depending on surface characteristics, such as reflectance and transmittance.

In this project, the colour sensor is in contact with conveyor belt for sensing the colour bottles. It can detect and measure a nearly limitless range of visible colours to certain degree

Solenoid valve

A solenoid valve is an electromechanically operated valve. Solenoid valves differ in the characteristics of the electric current they use, the strength of the magnetic field they generate, the mechanism they use to regulate the fluid, and the type and characteristics of fluid they control.

Solenoid valve are used to close, dose, distribute or mix the flow of gas or liquid in a pipe. The specific purpose of a solenoid valve is expressed by its circuit function. It is operated by PLC.

DC motor

The DC motor is a machine that transforms electric energy into mechanical energy in form of rotation. Its movement is produced by the physical behaviour of electromagnetism. DC motors have inductors inside, which produce the magnetic field used to generate movement.

In this project, DC motor is used to control the rotation for the conveyor belt.

Relay

The Relays are switches that open and close circuits electromechanically or electronically. Relays control one electrical circuit by opening and closing contacts in another circuit. As relay diagrams show, when a relay contact is normally open (NO), there is an open contact when the relay is not energized.

In our project, we are going to utilize 5V four channel relay.

A relay is an electrically operated switch. Many relays use an electromagnet to mechanically operate a switch, but other operating principles are also used, such as solid-state relays.

Miniature circuit breaker

A miniature circuit breaker (MCB) automatically switches off electrical circuit during an abnormal condition of the network means in overload condition as well as faulty condition. Nowadays we use an MCB in low voltage electrical network instead of a fuse.

An MCB functions by interrupting the continuity of electrical flow through the circuit once a fault is detected. It is two pole switches; rated current is 2A and insulation voltage is 250/440V AC.

Water pump

A submersible pump pushes water to the surface by converting rotary energy into kinetic energy into pressure energy. This is done by the water being pulled into the pump first in the intake, where the rotation of the impeller pushes the water through the diffuser.

The major advantage to a submersible pump is that it never has to be primed, because it is already submerged in the fluid. Submersible pumps are also very efficient because they don't really have to spend a lot of energy moving water into the pump.

Oil pump

The main purpose of an oil pump is to create pressure that allows oil pumping in the desired direction.

An oil pump, also called an electric oil pump, is a pump that can be fully submerged in oil. The motor is hermetically sealed and close coupled to the body of the pump.

An oil pump pushes oil to the surface by converting rotary energy into kinetic energy into pressure energy.

Float switch is an electrical ON/OFF Switch, which operates automatically when liquid level goes up or down with respect to specified level. The Signal thus available from the Float Sensor can be utilized for control of a Motor Pump or an allied electrical element like Solenoid, Lamps, Relays etc.

Float Switch contain hermetical sealed Reed Switch in the stem and a permanent magnet in the Float. As the Float rises or falls with the level of liquid the Reed Switch is activated by Magnet in the Float.