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 and Electronics Engineering)

DEPARTMENT OF ELECTRICAL ENGINEERING

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

This is to certify that the Project-Ireport 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 and Electronics Engineering) of Dr. Babasaheb Ambedkar
Technological University, Lonere (M.S.).

Place: Aurangabad
Date:

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

Head Project Guide
Electrical Engineering Department Electrical Engineering Department

Dr. S. P. Bhosle
Director
Marathwada Institute of Technology 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. Saundarmal, 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 project would not have
materialized.

I take this opportunity to convey our sincere thanks to Dr. S. M. Badave,Head of Electrical
Engineering Department, for providing guidance and wholehearted cooperation.

I am thankful to Dr. S. P. Bhosle, Director,Marathwada Institute of Technology, Aurangabad for

his encouraging attitude.

I also extend my genuine thanks to all the staff of Electrical Engineering Departmentfor
providing valuable guidance.I am also thankful of Prof. G. V. Lakhekar, and Mr. Sachin Giri for
their helpful discussion.

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)

 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.
 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 5
2.1 Literature Survey 5

3. SYSTEM MODELING 8
3.1 System Block Diagram 8
3.2 Components 8

4. PERFORMANCE ANALYSIS 13
4.1 Energy Product 13
4.2 Configuration & Testing 14
4.3 Software 18
4.4 Applications 19
4.5 Advantages 19

5. CONCLUSIONS 20
5.1 Conclusion 20
5.2 Future scope 20

References 21
 List of Figures

Figure Illustration Page

3.1 System Block Diagram 8

3.2 Push Botton 8
3.3 PLC Rail 9
3.4 MCB 3 Pole 9
3.5 Connector 10
3.6 Buzzer 11
3.7 Analog 12
3.8 Digital Input 13
4.1 Energy Product 14
 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 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

1
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.
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.

2
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 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
3
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 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 step 3.

4
 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. 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.
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 useof 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.In proceedingsof aece-iraj international conference, July 2013.
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, 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
5
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. 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.
The work carried out for this data 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 .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 compatibilitycooperate
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

6
controlled members .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 software details.

7
 3. SYSTEM MODELLING

3.1 System Block Diagram

Fig.3.1 System Block Diagram

3.2 Components

1. Push Button

2. PLC Rail Fig.3.2 Push Button

8
 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)

3. MCB 3 Pole

Fig.3.4 MCB 3 Pole

4. Contactor

9
 Fig.3.5 Contactor
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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 6. Analog

Fig.3.7 Analog

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.

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7. Digital Input

Fig.3.8 Digital Input

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 4. PERFORMANCE ANALYSIS

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 water and wastewater treatment. They feature high processing power, fast response times,

13
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 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.PLC based 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.

4.2 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. 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

14
and finally it checks.

4.2.1 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 ina variety of industries, including manufacturing, transportation.
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
includesa 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 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.

15
4.2.2 Configuration And Testing:-

16
17
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. 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.

18
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.

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.

19
 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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