Dr.

BABASAHEB AMBEDKAR TECHNOLOGICAL UNIVERSITY,

LONERE (M.S.)

Project-I Report on

“MODULAR INDUSTRIAL AUTOMATION WORKSTATION-II”

Submitted by
KRUSHNA BABASAHEB BHANDARE [1921261293040]
PRASHANT KONDAJI SABLE [2021261293045]

Under the Guidance of

PROF. V.D.SAUNDARMAL

In partial fulfillment of the award of

Bachelor of Technology (Electrical Engineering)

DEPARTMENT OF ELECTRICAL ENGINEERING

MARATHWADA INSTITUTE OF TECHNOLOGY
AURANGABAD (M.S.)
[2022-23]
 CERTIFICATE

This is to certify that the Project-I report entitled “MODULAR INDUSTRIAL AUTOMATION
WORKSTATION-II”, submitted by KRUSHNA BABASAHEB BHANDARE and PRASHANT KONDAJI
SABLE is the bonafied work completed under my supervision and guidance in partial fulfillment for the award of
Bachelor of Technology (Electrical Engineering) of Dr. Babasaheb Ambedkar Technological University, Lonere
(M.S.).

Place: Aurangabad
Date:

Dr. Mrs. S. M. Badave Prof. V.D.Saundarmal

Head Project Guide
Electrical Engineering Department Electrical Engineering Department

Dr. S. P. Bhosle
Director
MIT Aurangabad

Name & Signature of External Examiners with Date:

1) ____________________________________

2) ____________________________________
 ACKNOWLEDGEMENTS

Apart from the efforts of me, the success of this project depends largely on the
encouragement and guidelines of many others. I take this opportunity to express my
gratitude to the people who have been instrumental in the successful completion of this
project.

I am highly indebted to Prof.V.D.Saudarmal, for his guidance and constant

support. I can’t thank enough for his tremendous support and help. I feel motivated and
encouraged every time I attended his meeting. Without his encouragement and
guidance this seminar would not have materialized.

I take this opportunity to convey our sincere thanks to Prof. S. M. Badave,

Head of Electrical & Electronics Engineering Department, for providing guidance and
wholehearted cooperation.

I am thankful to Dr. S.P Bhosle, Principal, Marathwada Institute of

Technology, Aurangabad for his encouraging attitude.

I also extend my genuine thanks to all the staff of Electrical Engineering

Department for providing valuable guidance.

Finally, yet importantly, I would like to express my heartfelt thanks to my

beloved parents for their blessings, and my all friends and all others for their help,
backing and good wishes.

Finally, I would like to thank everybody who was important to the successful
realization of project report, as well as expressing my apology that I could not mention
personally one by one.

Krushna Babasaheb Bhandare (1921261293040)

Prashant Kondaji Sable (2021261293045)

i
 ABSTRACT

In today’s fast-moving, competitive industrial world, a company must be flexible,

cost effective for its survival. In the manufacturing industries there is great demand for
industrial automatio systems. The industrial automation is necessary in order to
streamline operations in terms of acceleration, reliabilit and system output. In today’s
economical world, automation plays gradually important role.
In the past few years, after the Industrial revolution industries have adopted several
automated machines for its purpose. In our project it is done by Programmable Logic
Controller (PLC) and SCADA. This work will provide low operational cost, low power
consumption, accuracy and flexibility to the system and at the same time it will provide
accurate volume of liquid in bottlebysaving operational time. The system sequence of
operation is being designed by ladder diagram. Automating repetitive tasks in the
industries increases the productivity. It reduces the probability of error and maintains
product quality. Traditional methods of mixing fixed quantities of different types of
liquids and filling them in bottles involve manual mixing of the constituent components
based on measurements and bottling of the mixture as desired. Manual handling of
such tasks is time consuming expensive and often lack consistency in product quality
due to human errors. A Laboratory Prototype of a Programmable Logic Controller
(PLC) based automated liquid mixing and bottle filling system is designed to automate
the control and mixing of two different liquids in predefined proportion and filling the
generated mixture in bottles to achieve quality control reduce human intervention and
improve productivity. The main goal of proposed system is to adopt automation in the
mixing industries like medicinal syrup manufacturing industries, colour mixing, and
food industry.

ii
 CONTENT

Acknowledgement i
Abstract ii
List of Figures iv

1. INTRODUCTION 1
1.1 Introduction 1

1.2 Organisation of Report 3

2. LITERATURE SURVEY 7
2.1 Literature Survey 7

3. SYSTEM MODELING 11
3.1 System Block Diagram 11
3.2 Components 11

4. PERFORMANCE ANALYSIS 16
4.1 Energy Product 16
4.2 Configuration & Testing 19

4.3 Software 21

4.4 Applications 22
4.5 Advantages 22

5. CONCLUSIONS 23
5.1 Conclusion 23

References 24

iii
 List of Figures

Figure Illustration Page

3.1 System Block Diagram 11

3.2 Push Button 11
3.3 PLC Rail 12
3.4 MCB 3 Pole 12
3.5 Connector 13
3.6 Buzzer 13
3.7 Analog 14
3.8 Digital Input 15
4.1 Energy Product 16

iv
 1. INTRODUCTION

1.1 Introduction

Automation is one of successful field in today’s world and it has become the backbone of control
engineering. Automation plays an increasingly important role in the world economy and in daily
experience. The goal is to provide plant operators and engineers the tools to monitor and control
their plant more efficiently. Automation is nothing but taking a system or process and making it
automatic by eliminating human work as much as possible. Mixing of liquids is a common process
in the paint industry; medical industry; chemical industry; pharmaceutical industry etc. The most
important step in mixing the liquid is defining the accurate proportion of constituent liquid element;
which can be effectively and accurately performed with the help of machinery without manual
intervention. This system is designed for automated level control; liquid mixing and filling of
bottles. The system is designed for filling the mixture of two liquids in equal proportion. It consists
of three sub system namely level controller; liquid mixer and bottle filler. The entire process is
controlled and automated with the help of PLC. PLCs are widely used in automation industry and
process control systems due to its ability for being user programmable. Automatic Liquid level
controller is designed to automate, monitor and control liquid level in the tank with the aim to
reducing cost and human intervention along with prevention of industrial accidents due to
overflowing of the tank. Level controllers are used for different industries as well as domestic
household purpose to automatically control the operation of motor thereby avoiding wastage of
resources. Automated liquid mixer performs mixing of different liquid in predetermined
proportions. The input to the control valve is given from the PLC. According to the ladder program
the valve will works and controls it‘s flow.

In this paper we are using PLC to control the Industrial Mixer. Programmable Logic Controller
(PLC) is a small computer used for automation of real-world processes, such as control of machinery
on factory assembly lines. The PLC usually uses a microprocessor. The program can often control
complex sequencing and is often written by engineers. The program is stored in battery-backed
memory and/or EEPROMs. Unlike general-purpose computers, the PLC is packaged and designed
for extended temperature ranges, dirty or dusty conditions, immunity to electrical noise, and is

1
 mechanically more rugged and resistant to vibration and impact.By implementing this project we
decreases man power, thus increase in production of the industry.
Over the years the demand for high quality, greater efficiency and automated machines has increased
in the industrial sector of different plants. Many plants require continuous monitoring and inspection at
frequent intervals. There are possibilities of errors at measuring and various stages involved with human
workers and also the lack of few features of microcontrollers. Thus this paper takes a sincere attempt
to explain the advantages the companies will face by implementing automation into them.The process
control of color making which is the most important process in any color plant like Asian paints and its
automation is the precise effort of this paper.In order to automate a color plant and minimize human
intervention, there is a need to develop a SCADA (Supervisory Control and DataAcquisition) system
that monitors the plant and helps reduce the errors caused by humans. While the SCADA is used to
monitor the system, PLC (Programmable Logic Controller)is also used for the internal storage of
instruction for the implementing function such as logic, sequencing, timing, counting and arithmetic to
control through digital or analog input/ output modules various types of machines processes. Systems
are used to monitor and control a plant or equipment in industries such as telecommunications, water
and waste control, energy, oil and gas refining and transportation.

Automation is used to reduce the human work and helps in increasing the production. PLC plays an
important role in the world of automation industry. It acts as major function in the automation field
which tends to reduce the complexity, increases safety and cost efficient. It requires continuous
monitoring and inspection at frequent intervals. There are possibilities of errors in parameter measuring,
human intervention at various stages and also the lack of advance features. Thus this paper takes a
sincere attempt to explain the benefits to the companies by making process automated. In order to
automate a plant and minimize human intervention, there is a need to develop a system that monitors
the plant and helps to reduce the errors caused by humans.PLC is the main part of the system which
makes the whole process simple, flexible and accurate. A color mixing and filling system with PLC
allows the user to mix the colors in different proportion and fill the bottle till a desired level without
wastage of the liquid. Ladder logic is used to perform the sequence of operation. The system is
controlled by a Allen Bradley Micrologix 1400 Series-B PLC which operates on 24V DC and is a
compact PLC which has a fixed number of inputs and outputs i.e., 32 number of digital input/output
ports and 6 number of analog input/output ports. In addition to this, the use of SCADA has also been
implemented for the monitoring of the entire system. In many industries, there are lots of industrial
problems like mixing process pneumatic control motor and drive control etc.

2
In manual system, there are so many disadvantages such as lack of Accuracy, Time delay problem,
loss of liquids, Time consuming etc.
So we design solve all industrial application like control, loop testing New logic
executionTrobleshooting of industrial problem.
A modular industrial automation workstation is a type of manufacturing system that is composed
of modular components that can be easily assembled and configured to perform a specific set of
tasks. These workstations are typically used in a wide range of industries, including automotive,
electronics, food and beverage, and pharmaceuticals. They typically include a combination of
robotic arms, conveyors, sensors, and control systems to automate the movement, handling, and
processing of materials. The modular design allows for flexibility and easy reconfiguration,
making it well suited for applications that require frequent changes to production processes

1.2 Organization Of Report

A digitally operating electronic apparatus which uses a programmable memory for the internal
storage of instructions by implementing specific functions such as logicsequencing, timing,
counting, and arithmetic to control, through digital or analog input/output modules, various
types of machines .
The S7-1200 controller provides the flexibility and power to control a wide variety of devices
in support of your automation needs. The compact design, flexible configuration, and powerful
instruction set combine to make the S7-1200 a perfect solution for controlling a wide variety of
applications. The CPU combines a microprocessor, an integrated power supply, input and output
circuits, built-in PROFINET, high-speed motion control I/O, and on-board analog inputs in a
compact housing to create a powerful controller. After you download your program, the CPU
contains the logic required to monitor and control the devices in your application. The CPU
monitors the inputs and changes the outputs according to the logic of your user program, which
can include Boolean logic, counting, timing, complex math operations, and communications
with other intelligent devices.The CPU provides a PROFINET port for communication over a
PROFINET network.

This paper is a complete application of automation. The various process of this system is
controlled by PLC. PLC is heart of the system and the system is controlled according to the

3
 programmed PLC. The block diagram of the whole process. There are seven inputs to the PLC out
of which five is the
output of the proximity sensor. The proximity sensor senses the presence
of the bottle at the conveyor belt. In this work metallic bottles are used which are detected by
aproximity sensor. Infra red sensor is another choice that may be used in place of proximity sensor.
When the bottle is sensed by the proximity sensor, a signal is sent to the PLC through signal
conditioning circuits. The PLC then operates the dc motors to start the mixing process and deliver the
mixture to the tank. In real time systems AC drives may be used for the purpose. Depending upon the
need, proportion and amount of two different liquid to be filled and mixed in bottle, the closing and
opening operation of valves connected to motors is controlled through PLC. PLC is a programmable
device developed to replace mechanical relays, timers and counters. PLCs are used successfully to
execute complicated control operations in a plant. The PLCs helped reduce the changeover time from
a month to a matter of just few days. PLC consists of an input/output (I/O) unit, central processing
unit (CPU) and memory. The I/O unit acts as the interface between PLC and real time systems. All
logic and control operations, data transfer and manipulation work is done by CPU. PLCs provide the
advantages of high reliability in operation, flexibility in control techniques, small space and computing
requirements, expandability, high power handling, reduced human efforts and complete programming
and reprogramming in a plant. The PLC is designed to operate in the industrial environment with wide
ranges of ambient temperature, vibration, and humidity and is not usually affected by the electrical
noise that is inherent in most industrial locations. It also provides the cost effective solution for
controlling complex systems
Basics of a PLC function are continual scanning of a program. The scanning process involves three
basic steps.
Step 1: Testing input statusFirst the PLC checks each of its input with intention to see which one has
status on or off. In other words it checks whether a switch or a sensor etc., is activated or not. The
information that the processor thus obtains through this step is stored in memory in order to be used
in the following steps.
Step 2: Programming executionHere a PLC executes a program instruction by instruction based on the
program and based on the status of the input has obtained in the preceding step, and appropriate action
is taken. The action might be activation of certain outputs and the results can be put off and stored in
memory to be retrieved later in the following steps.
Step 3: Checking and Correction of output statusFinally, a PLC checks up output signals and adjust it
has needed. Changes are performed based on the input status that had been read during the first step

4
and based on the result of the program execution in step two – following execution of step three PLC
returns a beginning of the cycle and continually repeats these steps.Scanning time = Time for
performing step 1+ Time for performing step 2+ Time for performing.

5
 2. LITERATURE SURVEY

2.1 Literature Survey:

Dr. A. S. C. S. Sastry, In this paper he concluded that the automated microcontroller-based liquid
mixing system provides a very satisfactory performance with a minimal percentage error. The
utilization of a microcontroller has been accomplished in the form of the at89s51 microcontroller.
The decision to use three microcontrollers was based on the elimination of idle time and the
optimization of the mixing process. in addition to this, the utilization of the various proposed
components such as dispensers, sensors, pumps, relays, dc motor and an input device was also
accomplished[5]. The presented work was published in (IJCSE) international journal on computer
science and engineering vol. 02, no. 08, 2010, 2648-2651. Shaukat N. PLC based, ”automatic liquid
filling process”, in this paper he concluded that this application of automation illustrating a PLC
based fully automatic untouched liquid filling and mixing system. The system meets the demand
of high speed production using the least mechanism requirements. The system has provedto work
effectively avoiding unnecessary spill or wastage of liquids. The system also provides high
accuracy and precision in proportion of liquid filling and mixing. Although proposed system
illustrates the mixing process of two liquids, any number of liquids may be mixed in varying
proportions. It is true that the use of PLC is a costly affair particularly for small industries but it
offers many advantages that overcome its cost [6]. This paper was published in

IEEE multi topic conference, 2002. Mallaradhya H. M., K. R. Prakash, “Automatic liquid filling to
bottles of different height using programmable logic controller. The system has proved to work
effectively avoiding unnecessary spill or wastage of liquids. The system also provides high
accuracy and precision in proportion of liquids mixed. Although proposed sys- 3 tem illustrates the
mixing process of two liquids, any number of liquids maybe mixed in varying proportions. It is
true that the use of PLC is a costly affair particularly for small industries but it offers many
advantages that overcome its cost. One of the additional features of the proposed system is the use
of SCADA that makes it controlled through a remote location. Complete monitoring of the system
is possible through SCADA and in fact the process may be stopped or started by SCADA screen.
This feature is particularly very useful in case if some fault occurs in the system [7].In proceedings
of aece-iraj international conference, July 2013.

6
 A brief survey of technologies explored during the past decade and some of them is given below
to provide an understanding of the level of research interest in this domain. In this paper [5],
researcher outlined the various phases of operation involved in the adaptation of a manually
operated boiler towards a totally automated boiler. The first part of the paper focuses on passing
the inputs to the boiler at a required temperature, so as to constantly maintain a particular
temperature in the boiler. The Air pre heater and Economizer helped in this method. And the paper
mainly focused on level, pressure and flow control at the various stages of the boiler plant. Thus
the temperature in the boiler is constantly monitored and brought to a constant temperature as
required by the power plant. The automation is further improved by constant monitoring using
SCADA screen which is connected to the PLC by means of communication cable. By means of tag
values set to various parameters in SCADA the entire process is controlled. At the automated power
plant, the boiler is controlled by Variable Frequency Drive (VFD) to put in action the required
processes to be carried out at the boiler. Thus the entire cycle is carried out as a paper and at various
stages each phase is detailed out. This paper has proved to be very efficient practically as the need
for automation grows day by day.This paper presented a SCADA system for a plant whose product
demand is varying according to the temperature [7]. This paper also gives an automatic method of
changing a production from one mode another.There is no manual shifting required. This paper
gives a way to get rid off excess production. It also provides the facility to the user to over ride the
any one of the unit hardware operation from the control room.Researchers developed a design of
re-usability using modular modeling techniques. Reimplementation of program of existing PLC
program based on formulization and visualization [4]. It is done by transformation of FSM in XML
format into IEC 61131-3 POUs and project is to be creating to control machine using new
controller.Prior to the development of data acquisition and control system, collecting data from
remote field instruments, distributed throughout the plant in huge manufacturing industries, was a
quite challenging and multifaceted task. The team of researcher has been developed an industrial
data acquisition and control systems equipped these industries with facilities to gather and process
data, and perform control actions right from a centralized location, i.e. control room, without
actually going to the plant. They introduction of programmable logic controllers (PLC) as a data
acquisition and control hardware in these systems increased its reliability and robustness. This
paper highlights the design work carried out to develop a cost efficient, simple, robust and
intelligent industrial standard data acquisition and control system for two physical field plants that
are 50 meters apart from the control room. This work highlights process control application and
indeed is an application of industrial electronics engineering. Thework carried out for this data

7
 acquisition and control system is in correlation with SCADA, DCS and totally integrated
automation, which is meant to optimize processes and manufacturing procedures at the same time
[8].At present, the PLC has been widely used in the industry area. But the shortcoming of this
controller appears along with the growth of the industry equipments. Such as inferior compatibility
cooperate with the new equipments, poor satisfaction of the high calculation and weak
communication and so on. Thus, there need technology to satisfy the increasing industry demands.
The soft PLC comes into the world from on kind of condition. The function of PLC is imitated
through software on the PC platform. But the soft PLC has shortage also. The sturdiness and
instantaneity is worse than the traditional PLC. Therefore, the embedded PLC combines the
advantages of traditional PLC and soft PLC, increase the computing power, express the advantages
of ladder diagram and open construction to bring a universal platform to the controlled members
[9].In this research paper, the group of authors took efforts on the improvement of demonstrating
how industrial temperature automation can be achieves using modest hardware and more refined
softwaredetails [10].
This paper reviews recent efforts in the literature to miniaturize nuclear battery systems. The potential
of a nuclear battery for longer shelf-life and higher energy density when compared with other modes
of energy storage make them an attractive alternative to investigate. The performance of nuclear
batteries are a function of the radioisotope(s), radiation transport properties and energy conversion
transducers. The energy conversion mechanisms vary significantly between different nuclear battery
types, where the radioisotope thermoelectric generator, or RTG, is typically considered a performance
standard for all nuclear battery types. The energy conversion efficiency of non-thermal-type nuclear
batteries requires that the two governing scale lengths of the system, the range of ionizing radiation
and the size of the transducer, be well-matched. Natural mismatches between these two properties
have been the limiting factor in the energy conversion efficiency of small-scale nuclear batteries.
Power density is also a critical performance factor and is determined by the interface of the
radioisotope to the transducer. Solid radioisotopes are typically coated on the transducer, forcing the
cell power density to scale with the surface area (limiting power density). Methods which embed
isotopes within the transducer allow the power density to scale with cell volume (maximizing power
density). Other issues that are examined include the limitations of shelf-life due to radiation damage
in the transducers and the supply of radioisotopes to sustain a commercial enterprise.
This review of recent theoretical and experimental literature indicates that the physics of nuclear
batteries do not currently support the objectives of miniaturization, high efficiency and high power

8
density. Instead, the physics imply that nuclear batteries will be of moderate size and limited power
density. The supply of radioisoto

9
 3. SYSTEM MODELLING

3.1 System Block Diagram

Fig.3.1 System Block Diagram

3.2 Components

1. Push Button
 Fig.3.2 Push Button

13

2. PLC Rail

Fig 3.3 PLC Rail

These two vertical lines are called the PLC Rail or Power Rail. Power rail is used to provide
the power source for each rung that makes a complete circuit. It can connect with AC or DC
source. The left vertical line represents the positive rail (consider as the phase)

14
3. MCB 3 Pole

Fig.3.4 MCB 3 Pole

4. Contactor

Fig.3.5 Contactor

15
 We use a contactor to turn on and off heavy and high voltage electrical devices such as motors,
fans, pumps, etc.

The reason that we use a contactor is to control these heavy high voltage electrical devices
indirectly and safely via a PLC and not to connect the PLC directly to these output
devices.

The main difference between a contactor and a relay is that a contactor is used for turning
on and off heavy high-voltage devices, but a relay is usually used to turn on and off
smaller low-voltage devices.

5.Buzzer

Fig.3.6 Buzzer

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Buzzers are devices that produce sound with usually a single frequency when powered by an
electrical source. They are more appropriate to be used as alarms rather than indicators for
obvious reasons. Nobody wants a buzzer being turned on for 24 hours a day because the START
button was pressed.

Buzzers can be creatively used in PLC control systems by varying the ON/OFF intervals or the ON
duration.

As an analogy, in primitive telephone circuits (the rotary ones), they send out electrical signals
with the same level of voltage BUT they vary in duration to represent a single digit of the dialed
telephone number.
What’s the advantage? Using buzzers allow us to convey different signals or messages to operators using
just a single output device. Does this mean that the pilot lights are less disadvantageous in terms of
notification Not necessarily, because pilot lights can allow you to instantly monitor the STATUS of a PLC
control system, while buzzers are used to notify at a certain LIMIT of a physical parameter of the PLC
control system. They certainly have their own place.

5. Analog

Fig.3.7 Analog

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6. Digital Input

Fig.3.8 Digital Input

4. PERFORMANCE ANALYSIS

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 4.1 Energy Product

Fig.4.1 Energy Product

PLC Specification :-

S7-1200

CPU 1211C AC/DC/RLY

DI 6×24v DC

DO 4×

PLC stands for "Programmable Logic Controller". The S7-1200 is a series of programmable logic controllers
(PLCs) manufactured by Siemens. These controllers are designed for small to medium-sized automation
applications and are suitable for a wide range of industries including manufacturing, building automation, and

19
 water and wastewater treatment. They feature high processing power, fast response times, and flexible
communication options. Some of the key features of S7-1200 PLCs include built-in Ethernet and USB ports,
support for multiple programming languages, and the ability to connect to a wide range of devices such as
sensors, actuators, and drives.
A Programmable Logic Controller, PLC is a digital computer used for automation. It is an interface
between program and the inputs. It is a programmable software.
A PLC is an example of a real time application and therefore used to control various devices. The PLC
works depending by the inputs given and their state, turning on/off its outputs. The user enters a program,
usually through software which gives the results. PLC is used in many “real world” applications. For all
application that needs some type of electrical signals, PLC works on the basis of inputs given by the
use. A PLC (Programmable Logic Controller) is a type of industrial computer that is used for automation
of industrial processes, such as control of machinery on factory assembly lines, amusement rides, or
lighting fixtures. PLCs are used in many industries and can range from small, modular devices to large,
rack-mounted systems.PLCbased automation systems have several advantages over traditional hard-
wired relay systems, including:
Flexibility: PLCs can be programmed to perform a wide range of tasks and can be easily reprogrammed to
adapt to changing requirements.
Reliability: PLCs are less prone to failure than hard-wired systems and can often continue to function even
if one or more components fail.
Diagnostics: PLCs can provide detailed diagnostic information, making it easier to identify and fix problems.
Monitoring and control: PLCs can be connected to networks and used to monitor and control processes remotely.
However, PLCs also have some disadvantages, including:
Cost: PLCs can be more expensive than traditional hard-wired systems, especially for small-scale
applications. Complexity: PLCs can be more complex to program and maintain than traditional systems.
Vulnerability: PLCs, like any computerized system, can be vulnerable to cyber-attacks if not properly
secured.
Overall, PLC-based automation systems are widely used in industry due to their flexibility and reliability.
However, the cost and complexity of these systems must be considered when evaluating their use for a
particular application.

Operation Of PLC :-

PLC works by a programmable support with some criteria. The PLC is connected with some
components and it is made to run with the help of program.

20
 PLC executes the program by one instruction at a time, where, if the first input is ON then it
should turn on the first output. Hence it already knows which inputs is on/off, from the previous
process. PLC updates the status of the outputs. First the PLC checks the input status and it scans .
the input by user defined programming. Next the process is executed and finally it checks the

Software Part :-

TIA (Totally Integrated Automation) PLC software is a program used to program and operate
programmable logic controllers (PLCs) from Siemens. It is used in industrial automation
applications to control and monitor machines and processes. The software is designed to work
seamlessly with Siemens hardware, such as PLCs, HMI (human-machine interface) devices, and
other automation components. It offers a wide range of features and tools, including programming
languages (such as Ladder Logic, Function Block Diagram, and Structured Text), debugging and
diagnostic tools, and integration with other software and systems. TIA PLC software can be used in
a variety of industries, including manufacturing, transportation, and
In software part we are going to discuss about the programs and the logics used. There
are some programming languages for control systems:
In our proposed device the Ladder Diagram (LD) is used. This is to interface the ON-
OFF button, programming logic. There are several programming softwares available but in our device
ladder logic is used. It is easy to understand and the programming is made more flexible
The Totally Integrated Automation Portal (TIA Portal), provides an engineering framework for
implementing automation solutions in all industries around the globe.
SCL is a high-level text based language that is easy to understand, yet provides many benefits over traditional
ladder programming.
The Totally Integrated Automation Portal (TIA Portal), provides an engineering framework for
implementing automation solutions in all industries around the globe. From designing,
commissioning, operating, and maintaining to upgrading automation systems, the TIA Portal saves
engineers time, cost, and effort. SIMATIC in the TIA Portal is the software for the configuration,
programming, testing, and diagnosis of all modular and PC-based SIMATIC controllers, and includes
a variety of user-friendly functions.

Modular SIMATIC® controllers have been optimized for control tasks and specially designed for
ruggedness and long-term availability. They can be expanded using plug-in I/O modules, function

21
 modules, and communication modules. Depending on the size of the application, you can select the
right controller from a wide range according to performance, quantity frameworks, and
communication interfaces. The modular controllers can also be used as fault-tolerant or fail-safe
systems.

SIMATIC PC-based controllers use the real time-capable software controller WinAC RTX or its fail-
safe variant WinAC RTX F on Windows® operating systems. Any PC applications, operator control
and monitoring tasks, as well as technological functions can be combined to form an overall
automation solution. The SIMATIC embedded bundles, with their highly rugged design and pre-
installed, ready-to-use automation software, allow the advantages of PC-based automation to be
implemented at the machine.

4.2 Configuration And Testing:-

22
23
 4.3 Software :-

PLC program for the hardware configuration of S7-1200 PLC :-

TIA Portal (Totally Integrated Automation) is an engineering framework created to program Siemens
devices
In this system we will consider S7-1200 PLC and TIA portal software for configuration.
For S7-1200 PLC we need TIA portal software for configuration of Hardware.
The SIMATIC S7-1200 system comes in four different models, with CPU 1211C, CPU 1212C,
and CPU 1215C, that may each be expanded to exactly fit the application requirements.
Here we consider CPU 1211 AC/DC/RLY for hardware configuration.

24
 TIA (Totally Integrated Automation) software is a program used for industrial automation
systems,specifically for Siemens SIMATIC automation systems. It is used for programming and
controlling PLCs (Programmable Logic Controllers) and other automation devices, as well as for
visualization and data management. TIA software includes a range of tools for tasks such as
configuring and programming PLCs, creating HMI (Human-Machine Interface) screens, and
connecting to other devices and systems. It is designed to work seamlessly with other Siemens
automation products, such as SIMATIC S7 controllers and SIMATIC HMI operator panels.
Ladder logic is a programming language that is used to program a PLC (Programmable Logic
Controller). It is a graphical PLC programming language which expresses logic operations with
symbolic notation using ladder diagrams, much like the rails and rungs of a traditional relay
logic circuit.
Ladder logic is a fast and simple way of creating logic expressions for a PLC in order to
automate repetitive machine tasks and sequences. It is used in a multitude of industrial
automation applications. Some industrial automation application examples where PLC ladder
logic is used.

4.4 Applications
1) Food processing technology

2) Beverage processing industry

3) Concrete industry

4) Paint industry

4.5 Advantages
1) Accurate & Proportional mixing of liquid

2) Reduction in operating costs as compare to manual process

3) Increasing production

4) Fully automatic system so that quality production achieved in less time 5) Efficiency & Maintenance easy.
6) Same system used for different purposes.

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7) Economical control of complex systems.

8) Can be reapplied to control other systems easily and quickly.

9) Sophisticated control can be done with computational abilities.

10) Programming is easier and reduces downtime through troubleshooting ability.

11) Reliability and durability of the components make PLCs likely to operate for years.

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 5. CONCLUSION

5.1 Conclusion

The most important aspect of any industry which is main part which is controlled using PLC. The method
that has to be used relies on varied objectives like superior quality, increased efficiency, high profit and other
such points depending upon the purpose of the company that implies it.With the prime objective of catering to
these necessities and the needs of the industrial sector, significance has been given here to automation.This
paper presented here has kept in mind, the ceaseless changes that are relentlessly taking place in the
contemporary scenario of the industrial segment. Emphasis has been given to the automation process that
isnow rapidly taking its place in all plants across the globe. The Paper has furnished itself to study the integral
parts of the entire process involved, their implementation andthe problems that mayshow uphave also been
given their due importance. The future work deals with the purification of water to the boiler and the air
circulation for the boiler to burn the fuel using sameautomation technique.
Making of product in industry is easy with the help of PLC.

This paper has shown how programmable logic controllers are a flexible and easily adaptable to typical
industrial equipment such as the industrial mixer. These controllers are programmed by using a
programming language called Ladder logic language. This language is easy to understand and is used by
engineers and technicians thus can be changed to suit any particular need. The Industrial mixer is one of the
several applications of the programmable logic controller to the control of an industrial process. This helps
to eliminate huge costs.

5.2 Future Scope

Modern industrial Internet of Things (IIoT) technologies, edge and cloud software, machine learning (ML),
artificial intelligence (AI) and low-code platforms are enabling this type of advanced automation and putting
companies on the path to benefitting from artificial intelligence of things (AIoT) implementations.
Industrial automation can and will generate explosive growth with technology related to new inflection
points: nanotechnology and nanoscale assembly systems; MEMS and nanotech sensors (tiny, low-power,
low-cost sensors) which can measure everything and anything; and the pervasive Internet, machine to
machine

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