INFORMATION ON SK_SP-TA

FOR COURSE

Course Code & Name : BPB33603 PROGRAMMABLE LOGIC CONTROLLER AND APPLICATION
PLOs : 5

Please tick ( 🗸 ) in the box provided.

Knowledge Profiles (SK) A programme that builds this type of knowledge and develops the attributes listed below is typically
achieved in 4 years of study
SK1 A systematic, theory-based understanding of the natural sciences applicable to the sub-discipline
Conceptually-based mathematics, numerical analysis, statistics and aspects of computer and information
SK2
science to support analysis and use of models applicable to the sub-discipline
A systematic , theory-based formulation of engineering fundamentals required in an accepted sub-
SK3
discipline
Engineering specialist knowledge that provides theoretical frameworks and bodies of
SK4
knowledge for an accepted sub-discipline
SK5 Knowledge that supports engineering design using the technologies of a practice area
SK6 Knowledge of engineering technologies applicable in the sub-discipline 🗸
Comprehension of the role of technology in society and identified issues in applying
SK7 engineering technology: ethics and impacts: economic, social, environmental and
sustainability
SK8 Engagement with the technological literature of the discipline

Definition of Broadly-Defined Problem Solving (SP)

Broadly-defined Engineering Problems have characteristic SP1 and some or all
No. Attribute
of
SP2 to SP7:
Cannot be resolved without engineering knowledge at the level of one or
SP1 Depth of Knowledge Required more of SK 4, SK5, and SK6 supported by SK3 with a strong emphasis on 🗸
the application of developed technology
Range of conflicting
SP2 Involve a variety of factors which may impose conflicting constraints.
requirements
SP3 Depth of analysis required Can be solved by application of well-proven analysis techniques 🗸
Belong to families of familiar problems which are solved in well-accepted
SP4 Familiarity of issues
ways
May be partially outside those encompassed by standards or codes of
SP5 Extent of applicable codes
practice
Extent of stakeholder
Involve several groups of stakeholders with differing and occasionally
SP6 involvement and level of
conflicting needs
conflicting requirements
SP7 Interdependence Are parts of, or systems within complex engineering problems 🗸

Range of Engineering Activities (TA)

No. Attribute Broadly-defined activities
Involve a variety of resources (and for this purposes resources includes people,
TA1 Range of resources
money, equipment, materials, information and technologies)
Require resolution of occasional interactions between technical, engineering and
TA2 Level of interactions
other issues, of which few are conflicting
TA3 Innovation Involve the use of new materials, techniques or processes in non-standard ways
Consequences to
Have reasonably predictable consequences that are most important locally, but
TA4 society and the
may extend more widely
environment
TA5 Familiarity Require a knowledge of normal operating procedures and processes
Introduction of PLC
 An industrial computer with specific functions, a Programmable Logic
Controller (PLC) is essential for regulating machinery and processes in production
lines, manufacturing operations, and other industrial settings. PLCs are designed to
withstand challenging conditions by taking over the role of conventional relay logic
systems yet also have several important features that increase their usefulness.
Flexibility is a crucial quality that allows engineers to quickly alter functionality in
dynamic industrial environments where processes change on an ongoing schedule.
PLCs are incredibly reliable in terms of pertains to resisting harsh environments
including fluctuating temperatures, high humidity, and electrical noise. PLCs embrace
flexibility with designs that let users add input/output (I/O), connectivity, and other
accessory modules to extend capabilities seamlessly. A crucial component of industrial
automation, where timing is everything, is real-time processing, which guarantees
quick input replies with little latency. PLCs connect to the outside world via various
digital and analog inputs and outputs, including actuators, switches, sensors, and other
equipment necessary for industrial operations.

Basic PLC Operations

PLC comprises fundamental elements such as input signal modules, a central

processing unit (CPU), output signal modules, and a programming device. The specific
types of input and output signal modules utilized by a PLC are contingent upon the
characteristics of the connected devices. Input signal modules play the role of
translating signals from input devices into logic signals, facilitating interpretation by
the CPU. The CPU, in turn, utilizes these input values and executes the user program
stored in its memory. Subsequently, the CPU dispatches signals to update the statuses
of output devices. Output signal modules then convert these signals into either digital
or analog formats, enabling control over output devices. The programming device
serves the purpose of entering or modifying the PLC's program, as well as monitoring
or adjusting stored values. Once the program and associated variables are inputted,
they are stored within the CPU. For instance, a control system may integrate Human
Machine Interfaces (HMIs) to oversee and manage machinery or processes, although
HMIs are distinct entities closely collaborating with the PLC.
Wiring Diagram
Input / Output devices

Input device Address number Output device Address number

PB1 I0.0 SOL1 Q0.0
LS1 I0.1 SOL2 Q0.1
LS2 I0.2 Conveyor A Q0.2
LS3 I0.3 Conveyor B Q0.3
PH1 I0.4 Gripper Q0.4
PH2 I0.5 Release Q0.5
PH3 I0.6 MV1 Q0.6
PH4 I0.7 MV2 Q0.7
PH5 I1.0

PLC Tags
Robot Arm Function Block Ladder Diagram
Automated Sorting Station
Reset Counter for sorting bin full
Human Machine Interface (HMI)
Simulation Ladder Diagrams

System Enabled and SOL 1 activated.

Conveyor A enabled and feedback to HMI

 Gripper Enabled and SOL 2 Activated

Release Command and Conveyor B Activate

Automated Sorting system, Master encoder reference follow to MV rejects with delay timer
Counter Max reached for Thicker and Thickest
Timing Diagram
ANALYSIS & DISCUSSION

The results of this lab assessment were good since the operations and conditions
of the robot System are done according to the company's desire for their factory. The
experimental part, which is a working configuration of the robot, proved to be more
demanding than expected.
This kind of robot is seen in many automated factories. As is apparent from the figure, this
robot picks up a carrom coin workpiece being carried on conveyor A and places it on conveyor
B. Using the Limit Switch LS2 (I0.2), you should be able to rotate the robot arm clockwise
SOL1 (Q0.0). Using the Limit Switch LS1 (I0.1), you should be able to rotate the robot arm
counterclockwise SOL2 (Q0.1). If both “Limit Switch” are pressed simultaneously, then the
robot arm may not rotate in either direction (Lock-out!). When the start button PB1 (I0.0) is
pressed, the robot rotates its arm clockwise SOL1 (Q0.0). When the robot arm has moved to the
position of the work on the conveyor A, The Limit Switch LS1 (I0.1) detect the arm and stop the
rotation. Then Conveyor A (Q0.2) will turn on and carry the carrom coin work piece to the
arm. When The Photoelectric sensor PH1 (I0.4) Detect work piece, the conveyor A (Q0.2)
will stop and gripper (Q0.4) will start to grasp the work. When the arm has grasped the work
conform by the sensor LS3 (I0.3), it rotates counterclockwise SOL2 (Q0.1). When the arm has
rotated to the position of conveyor B, LS2 (I0.2) will detect the arm and release (Q0.5) the work
Piece. Conveyor B (Q0.3) will turn on.

This is a continuation industrial process control for sorting carrom coin based on their
thickness. The carrom coin will be pack are differentiated with its thickness, thickest (height
= 7.5mm), thicker (height = 7.2mm and thick (height= 7mm). Photoelectric sensor (PH2)
serves as the data input to the shift register. The signal output from this sensor turns ON when
a carrom coin work piece has been detected; otherwise, it remains OFF. N Photoelectric sensor
(PH5) is used as a clock generator that serves as the clock input to the shift register. It
generates one pulse each time the product, spaced at a fixed interval from each other, has travelled
a predetermined distance. For the work piece with the Thickness as thickest, it will be
detected by the Photoelectric sensor PH4 (I0.7) and then sorted by the magnetic valve MV2.
Then for the work piece with the thicker height, it will be detected by the Photoelectric sensor
PH3 (I0.6) and then sorted by the magnetic valve MV1 (Q0.6) and lastly for the work piece
with the thick height, it will fall directly into the container.

From the moment a carrom coin work piece is detected by PH2, it is traced by the
shift register until the work piece arrives at the predetermined position on the conveyor where
it is ejected by the magnetic valve MV1 or MV2. The carrom coin will be count according to
its thickness. If any of the container reach the quantity of 19, the whole operation will be stop
until the reset button is pressed. The operation will continue without pressing the start button.
The reset button will only reset the counter which is 19... the other product will resume.
the counting.
CONCLUSIONS & RECOMMENDATIONS

In conclusion, Programmable Logic Controller (PLC) configuration and

programming are essential components of industrial automation systems. Control logic
that is implemented by PLCs is defined by PLC programming.

These assignments require use of SIEMENS S7-1200 since the materiality and
capabilities of the PLC are being enhanced. The framework works well under typical
operating conditions and aids in the design of the soft drinks beverages mixer system
because the PLC ladder diagram is used. To facilitate debugging, the wiring and
installation process is simplified, and addresses are assigned to the PLC input and output
devices. Costs in the labor or academic sectors are primarily reduced by this study.

There are few recommendations can be done to make the soft drinks beverages
mixer system better such as:
● Having a user interface. Provide a user-friendly Human Machine Interface
(HMI) so that operators can communicate with the PLC system as HMI
provides operators with a graphical interface to monitor and control
processes. For simplicity of use, include touch screens or other input
devices.
● Provide a cleaning system in all the tanks. To ensure cleanliness and
prevent cross-contamination, include an automated cleanup system to
flush and wash the mixing equipment after each completed operation.
● Include a safety system. Include safety interlocks or emergency stop
buttons to ensure worker safety and avoid accidents if the system is out of
control.
REFERENCES

 Basics of PLCs - sitrain.us (2016) Basic of PLCs. Available at:

https://sitrain.us/step/pdfs/version2/Basics_of_PLCs.pdf (Accessed: 29
November 2023).

 Electronics, A. (2023) Step-up vs. step-down Transformers, Arromw.com.

Available at:
https://www.arrow.com/en/research-and-events/articles/step-up-and-step-down-
transformers (Accessed: 28 November 2023).
 ASSESSMENT COVERSHEET
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Section A: Submission Details
Programme : Bachelor of Engineering Technology (Hons) in Electrical
Course Code & Name : BPB33603 / BPB31403 & Programmable Logic Controller and Application
Course Lecturer(s) :
Submission Title : LABORATORY 2
Deadline : Day 13 Month JANUARY Year 2024 Time 5.00 PM
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