automation of dual extruder hydraulic power pack full report 2015 done at apollo tyres kalamassery...

AUTOMATION OF

DUAL EXTRUDER HYDRAULIC POWER PACK

PROJECT REPORT

Submitted by

AJAY P RAJ - Reg:11021421

ATHULDEEP N - Reg:11021432

HARI R - Reg:11021441

PRINCE JOSE - Reg:11021452

In partial fulfillment of the requirements

for the award of the degree of

BACHELOR OF TECHNOLOGY

IN

ELECTRONICS AND COMMUNICATION ENGINEERING

MAY, 2015

DEPARTMENT OF ELECTRONICS & COMMUNICATION ENGINEERING

SREE NARAYANA GURU INSTITUTE OF SCIENCE AND TECHNOLOGY

MANJALY, MANNAM P.O, NORTH PARAVUR -683520.

DEPARTMENT OF ELECTRONICS & COMMUNICATION ENGINEERING

SREE NARAYANA GURU INSTITUTE OF SCIENCE AND TECHNOLOGY

MANJALY, MANNAM P.O, NORTH PARAVUR -683520.

CERTIFICATE

Certified that the Project report entitled AUTOMATION OF DUAL

EXTRUDER HYDRAULIC POWER PACK is submitted by AJAY P RAJ - 11021421,

ATHULDEEP N - 11021432, HARI R -11021441 & PRINCE JOSE - 11021452, is the

bonafide report of the Project done by them under our guidance, in partial fulfillment for the

award of Bachelor of Technology in Electronics and Communication Engineering of M G

University during the year 2014 – ‘15.

Guide HOD Dean

Automation of Dual Extruder Hydraulic Power Pack i

Electronics and Communication Engineering Department SNGIST

ACKNOWLEDGEMENT

We are grateful to the Chairman, Prof. C K Renjan, and Management of Sree

Narayana Guru Institute of Science and Technology for providing the facilities for the

completion of our task.

We extend our gratitude to Dr K.S. Divakaran Nair, Director of Sree Narayana

Guru Institute of Science and Technology for his continuous support.

It is our privilege to thank Prof. Sureshkumar V, Dean of Engineering, Sree

Narayana Guru Institute of Science and Technology for his blessings and encouragement.

We would also like to thank Prof. John J Palakkapilly, Head of the Department

of Electronics and Communication Engineering for his inspiration and guidance. May we

express our heartfelt thanks to our guides for their valuable guidance and advice related

to this work.

We express our sincere gratitude to our guide Mr.Sumesh A.S for his valuable

guidance, constant support and co-operation he had given to us throughout our project work.

We thank all the faculty members of Department of Electronics and

Communication Engineering for all the help extended to me and for motivating me. We

also extend our gratitude to technical staff in the Lab, for all their support and help.

We, on this occasion, remember the valuable support and prayers offered by our

family members and friends which were indispensable for the successful completion of

this work.

Automation of Dual Extruder Hydraulic Power Pack ii


ABSTRACT

Tire components such as tread, sidewall, and apex are prepared by forcing uncured

rubber compound through an extruder to shape the tire tread or sidewall profiles. Extrusion is

one of the most important operations in the tire manufacturing process because it processes

most of the rubber compounds produced from the mixing operation and then prepares various

components for the ultimate tire building operation.

The Extruder mouth operations and die clamping is performed using hydraulic

cylinders. A hydraulic power pack and directional controllers are used to perform this

operation. At present in hydraulic power pack two hydraulic pumps are running continuously

throughout the production about 20hrs per day. Hence a large amount of energy is consumed

and production cost increases.

So in order to solve this problem we are adding a PLC (Programmable logic

controller), which controls the extruder mouth operations. So the two hydraulic pumps works

about 4 hours & hence reduces the power consumption.

Automation of Dual Extruder Hydraulic Power Pack iii


TABLE OF CONTENTS

CHAPTER

NUMBER TITLE

PAGE

NUMBER

ABSTRACT ii

TABLE OF CONTENTS iii

LIST OF TABLES v

LIST OF FIGURES vi

LIST OF ABBREVATIONS viii

1 INTRODUCTION

1.1 ABOUT THE FIRM

1.2 OBJECTIVE

1.3 SCOPE

1. 4 EXPECTED OUTCOMES

9

9

10

10

11

2 LITERATURE SURVEY 12

3 THEORY AND DESIGN 14

3.1 TYRE MANUFACTURING PROCESS

3.2 THREAD EXTRUSION

3.3 EXTRUDERS

3.4 BLOCKDIAGRAM

3.5 PROGRAMMABLE LOGIC CONTROLLERS

3.6 FLOW CHART

14

16

17

18

19

33

Automation of Dual Extruder Hydraulic Power Pack iv


4

5

6

7

3.7 PLC ARCHITECTURE

3.8 CIRCUIT DIAGRAM

3.9 SOLENOID VALVE

3.10 SOFTWARE DESCRIPTION

IMPLEMENTATION

RESULT

CONCLUSION

FUTURE SCOPE

APPENDIX

REFERENCES

35

36

40

41

45

53

55

56

57

66

Automation of Dual Extruder Hydraulic Power Pack v


LIST OF TABLES

TABLE

NUMBER TITLE

PAGE

NUMBER

3.1 SYSTEM REQUIREMENTS 41

4.1 TIMERS 51

4.2 SET AND RESET INSTRUCTIONS 51

4.3 CALCULATE INSTRUCTION 51

4.4 BIT LOGIC CONTACTS AND COILS 52

4.5 DATA TYPES FOR THE PARAMETERS 52

4.6 CONVERT (CONV) INSTRUCTION 52

Automation of Dual Extruder Hydraulic Power Pack vi


LIST OF FIGURES

FIGURE

NUMBER TITLE

PAGE

NUMBER

3.1 THREAD EXTRUSION 16

3.2 BLOCK DIAGRAM 18

3.3 HISTORY OF PLC 20

3.4 PLC 21

3.5 INSIDE PLC 22

3.6 INPUT MODULES 1 23

3.7 INPUT MODULES 2 23

3.8 DIGITAL VS ANALOG MODULES 24

3.9 OUTPUT MODULES 1 25

3.10 OUTPUT MODULES 2 25

3.11 POWER SUPPLY 26

3.12 NETWORK INTERFACE 27

3.13 PLCS AS A PART OF CONTROL SYSTEM 27

3.14 SIEMENS-S71200 PLC 29

3.15 PLC ARCHITECTURE 35

3.16 CIRCUIT DIAGRAM 36

3.17 SIEMENS S71200 ANALOG I/O MODULE 38

Automation of Dual Extruder Hydraulic Power Pack vii


3.18 POWER DISTRIBUTION NETWORK 39

3.19 SOLENOID VALVE 40

3.20 PORTAL VIEW & PROJECT VIEW 42

3.21 DRAGGING AND DROPPING 44

4.1 CREATING NEW PROJECT 45

4.2 CONFIGURING PROJECT 46

4.3 INSERTING &CONFIGURING CPU1 46

4.4 INSERTING &CONFIGURING CPU 2 47

4.5 INSERTING &CONFIGURING CPU 3 47

4.6 INSERTING & CONFIGURING DIGITAL I/O

MODULE &ANALOG I/O MODULE 1 48

4.7 INSERTING & CONFIGURING DIGITAL I/O

MODULE & ANALOG I/O MODULE 2 49

4.8 INSERTING TAGS 49

4.9 LADDER DIAGRAM DEVELOPMENT 50

Automation of Dual Extruder Hydraulic Power Pack viii


LIST OF ABBREVIATIONS

PLC - PROGRAMMABLE LOGIC CONTROLLERS

MCB - MINIATURE CIRCUIT BREAKER

MPCB - MOTOR PROTECTION CIRCUIT BREAKER

CIM - COMPUTER-INTEGRATED MANUFACTURING

GUI - GRAPHIC USER INTERFACES

NC - NORMALLY CLOSED

NO - NORMALLY OPEN

Automation of Dual Extruder Hydraulic Power Pack


CHAPTER 1

INTRODUCTION

The process of tyre manufacturing is the art of processing the some materials such as

Rubber and rubber additives, Fabric reinforcement (tyrecords), Wire rein forcements

(beadwire) and assembling the various components into the final product. The process of

tyre manufacturing is complicated by the numerous raw materials, equipments and process

used for the same. The process consist of mainly of mix formulation, compounding, molding,

vulcanization, and finishing, accompanied further by the process of manufacturing tyre cords

and bead wires.

Tire tread, or the portion of the tire that comes in contact with the road, consists of,

tread cap and tread base. Since there are at least two different rubber compounds used in

forming this complex tread profile, the extruder system consists of two different extruders

sharing an extruder head. Two rubber compounds are extruded simultaneously from different

extruders and are then merged into a shared extruder head. The next move is to a die plate

where the shape and dimensions are formed, and then through a long cooling line from 100 to

200 feet long to further control and stabilize the dimensions. At the end of the line, the tread

is cut according to a specific length and weight for the tire being built.

1.1 ABOUT THE FIRM

APOLLO TYRES LIMITED is one of the leading manufacturers of automotive

tyres. Other products are tubes and flaps for heavy-duty trucks, passenger cars, tractors,

light commercial vehicles and new generation vehicles. The company is technical

collaboration with CONTINENTAL AG GERMANY.

Apollo tyre is a leader in Indian tyre industry and a significant global players

providing costumer delight and enhance shareholder value. The history of Apollo, the company

can be tracked back to the seventies when hardnosed MNC's and Indian tyre majors

dominated. In the tyre industry largest tyre company in the world. Apollo is the fastest

growing tyre company in India, in the world tyre. It is the first company in India to obtain

IS09007 certification for all the operations. The current production is 100 tons per day.

There are 1625 employees in the organization.

Automation of Dual Extruder Hydraulic Power Pack 10


Company has a vision to create an enterprise committed to quality. They aim to

create superior and distinct products and services in pursuit of total customer satisfaction.

1.2 OBJECTIVE

Tire components such as tread, sidewall, and apex are prepared by forcing uncured

rubber compound through an extruder to shape the tire tread or sidewall profiles. Extrusion is

one of the most important operations in the tire manufacturing process because it processes

most of the rubber compounds produced from the mixing operation and then prepares various

components for the ultimate tire building operation.



operation .At present in hydraulic power pack two hydraulic pumps are running continuously


and production cost increases. So in order to solve this problem we are adding a PLC

(Programmable logic controller), which controls the extruder mouth operations based on

pressure. So the two hydraulic pumps works about 4 hours & hence reduces the power

consumption.

1.3 SCOPE

Control engineering has evolved over time, In the past humans was the main

method for controlling a system. More recently electricity has been used for

controlling and early electrical control was based on relays. These relays allowed power to

be switched on and off without a mechanical switch. It is common to use the relay to

simple logical control decision. The development of low cost computer has brought

the most recent revolution, the Programmable logic controller. A PLC is a

device that was invented to replace the necessary sequential relays circuit

machine controls. The PLC works by looking at its input and depending upon their

state, turning on/off its outputs. The user enters a program, usually via software, that

gives desire results.

As a part of our course we did our project work on Dual Extruder Hydraulic

Power Pack using PLC in Apollo Tyres Ltd, Kalamassery.



1. 4 EXPECTED OUTCOMES

In an industry power consumption is very important. For the thread extrusion operation

in the current system it is very energy consuming about 90KWH. We are attempting to

reduce the power consumption by adding a PLC for the control of extruder operation. We

expect a reduction of energy consumption from 90KWH to 20KWH. That is 70KWH is

reduced.



CHAPTER 2

LITERATURE SURVEY

2.1 Energy Conservation in centrifugal pump with variable frequency drive

including SCADA, PLC and HMI

Mr. Priyank Dave ,GEC Valsad

IJIRSET Vol. 2, Issue 5, May 2013

This paper introduces Energy Conservation in centrifugal Pump. Pumping systems

account for nearly 20% of the world’s electrical energy demand and range from 25 -50% of

the energy usage in certain industrial plant operations .Pumping systems consume a

significant portion of the electricity, Variable frequency drives (VFD’s) are often

recommended as a way to save pumping energy. Actual energy savings will vary greatly

depending on how the discharge pressure of the constant speed pump is controlled and how

it is operated after the VFD is installed.In the present work,the flow of pump has been

controlled by two different methods, experimental work has been carried out and comparetive

statement is given.

2.2 Constant Pressure Water Supply System Control Using PLC

Peng Sun, Dalian University, China

IJAPE Vol.3,Issue 8,Sept 2012

On the basis of the constant-pressure principle and variable-frequency principle

applied to traditional water supply system, this paper presented the overall structure of water

supply system using plc (programmable logic controller) as main controller, and newly used

the switched adaptive control principle to optimize water supply quality. The systematic

analysis was carried on by combining the system with its mathematical model. The simulation

data using visual c++ confirms the system’s rationality, stability and superiority.Water flows

into the switched adaptive control system through pipelines and then will be delivered to

every user with constant-pressure. The system can automatically adjust and switch

operating parameters according to changes of water consumption and the demand of

constant -pressure. As known to us all, water is delivered to each user through pipelines



from water company. The system using switched adaptive control algorithm can provide

stable, efficient and reliable water supply.

2.3 Energy-efficiency improvement opportunities in pumping systems,

LK Reynolds,Mouchel Group Ltd

Boxall & Maksimovi Vol.1,June2007

Pump systems consist of pumps, driver, pipe installation and controls (such as ASDs

or throttles) and are a part of the overall motor system. Below some of the energy efficiency

opportunities for the pumping system are presented.Also, American Society of Mechanical

Engineers (ASME) has published a standard that covers the assessment of pumping systems,

which are defined as one or more pumps and those interacting or interrelating elements that

together accomplish the desired work of moving a fluid.

http://electrical-engineering-portal.com/14-energy-efficiency-improvement-opportunities-in-pumping-systems

https://www.asme.org/

https://www.asme.org/



CHAPTER 3

THEORY AND DESIGN

3.1 TYRE MANUFACTURING PROCESS

Pneumatic tyre is a high performance composite product. The raw materials used

for its manufacture can be divided into three groups.

Rubber and rubber additives

Fabric reinforcement( tyrecords)

Wire reinforcements(beadwire)

The process of tyre manufacturing is the art of processing the above materials and

assembling the various components into the final product. The process of tyre

manufacturing is complicated by the numerous raw materials, equipments and process used

for the same. The process consist of mainly of mix formulation, compounding, molding,

vulcanization, and finishing, accompanied further by the process of manufacturing tyre cords

and bead wires.

COMPOUND MIXING

Mixing the required additives into rubber makes a compound. This mixing is

accomplished in two or more steps using a Ban bury mixer. The mixing is done in the

chamber of the Ban bury mixer under high shear and pressure using the rotors of the

machine so that the ingredients are uniformly dispersed inside the rubber matrix. Different

rubber compounds (differing in the recipe) are used in the different components of the tyre.

EXTRUSION

Here, components of the tyre like tread and sidewall are prepaied from rubber

compounds using a Dual Extruder. Extrusion is the process by which the rubber

compound is given definite continuous shape. A thin sheet of rubber compound prepared



using a small 2-roll calendar is applied to the bottom side of the tread. This component is

called tread cushion. The continuous profile is then cooled, and cut to require length,

which is used in the assembling of tyre at tyre building.

CALENDERING

Fabric calendering is the process of coating both sides of the dipped fabric using

rubber compound. This is accomplished using a 4-roll 'Z' type calender. The coated

fabric is cooled and wound in liners (in continuous length) to avoid sticking. This goes to

the next stage of ply cutting.

PLY CUTTING (BIAS CUTTING)

For assembling a tyre several plies are used. For example a 16PR Nylon truck tyre

uses 8 plies and two breakers. Each ply is cut from the coated fabric rolls prepared by

calendering. This process of ply cutting is accomplished in a Bias Cutter. Each ply is cut at

definite width and angle and wound in liners. The cut plies then go to 3-roll calender for

squeegee application. Components like chafer and flipper are also made at the Bias Cutter.

These are further slit using a slitter into smaller widths and wound into rolls. Chafer rolls from

slitter go to the tyre building and flipper rolls go to the bead flipping.

TYRE BUILDING OR TYRE ASSEMBLING

Tyre Building is the process of assembling various components into the semi finished

product called a "Green Tyre". A Tyre Building Machine accomplishes this. The

components like Drum Squeegee, Plies, (with squeegee applied on to it) are assembled using a

Tyre Building Drum. The flipped beads are applied from the ends and locked in using the ply

ends, breaker and chafer are applied next. Finally, the tread and sidewalls are applied. The

assembly (Green Tyre) is taken out after collapsing the drum.

TYRE CURING

The green tyre is inspected and then applied with a Lubricant on the inside and an

anti-blemish paint on the outside sidewall area. The Green Tyre is also awed to facilitate

easy removal of any trapped air during the final shaping and molding operation. The Green

Tyre is shaped and given the final contour using the appropriate tyre curing moulds (fitted to

tyre curing presses) by the application of pressure and temperature. The rubber compound

gets vulcanized during curing and becomes tough and elastic and provides all the desired

properties required in the tyre.



The curing times vary depending upon the size of the tyre varying from 18' for a

Passenger car tyre to one hour for Truck tyres.

POST CURE INFLATION

Nylon tyres after press curing are kept under high-pressure inflation to help shape

retention and to reduce growth in service. This process of cooling the tyre under high

inflation pressure is called Post Cure Inflation (PCI).

INSPECTION

The tyres after PCI are subjected to vent trimming. The tyres are then inspected

100% for visual defects. The tyres are also statistically sampled and tested for conformance

to BIS specifications and then warehoused.

3.2 THREAD EXTRUSION

Extrusion is a process in which polymeric materials, in the form of powder, granules,

trip or melt, are converted into products of controlled cross-section in a continuous fashion,

by softening (plasticising) the material using heat and/or pressure, forcing the softened

material through and orifice (die) and maintaining the desired cross-section by cooling or by

chemical reaction.

In the case of thread extrusion, Extrusion means “forcing the rubber compound

through a die”. The die is metal mould in the shape of the tyre component to be

manufactured. This distributes the rubber volume into the appropriate final shape and

dimensions.

Figure 3.1: Thread extrusion



After heating the rubber to soften it, the tread is extruded to create a cross sectional

shape. The extruded tread is completely cooled and cut into lengths suited for individual

tyres.

3.3 EXTRUDERS

Based on extruder design Extruders are classified as follows.

3.3.1 Ram Extruder

In its simplest form an extruder is analogous to icing a cake. The polymer is fed to the

cylinder (barrel) in a plasticised state. The cylinder is heated to maintain the softened state.A

hydraulically actuated ram (plunger) forces the material through a die clamped to the end of

the cylinder. A ram extruder is not truly continuous but is appropriate for short product

lengths, eg strip for tyre tread. Also the temperature distribution, and hence viscosity

distribution, is poor.

3.3.2 Gear Pump Extruder

Gear Pump mechanisms, meshing cogs, work well on pre-plasticised , low viscosity

materials, giving a positive throughput but are poor for plasticising. Gear pumps are now

used between a single screw extruder and the die to maintain constant throughput.

3.3.3 Single Screw Extruder

A rotating Archimedean screw in a cylinder ensures the continuous transfer of

material from the feed (hopper) end to the die end. Heat is supplied from external heater

bands or jackets.With a simple screw design the conducted heat sets up unwelcome

temperature gradients in the material and a long cylinder would be required for operating at a

reasonable throughput. The limiting factor would be the length of the screw which is

restricted by the drive torque it can sustain. On smaller extruders (35 mm diameter screw)

length/diameter (L/D) ratios go up to 35:1 but on larger extruders (200 mm diameter) L/D

ratios approach 40:1.



3.4 BLOCK DIAGRAM

RUBBER MATERIALS FOR BASE AND CAP

Figure 3.2: Block diagram

Tire tread, or the portion of the tire that comes in contact with the road, consists of

thread cap and thread base. Since there are at least two different rubber compounds used in

forming this complex tread profile, the extruder system consists of two different extruders

sharing an extruder head. Two rubber compounds are extruded simultaneously from different

extruders and are then merged into a shared extruder head. The next move is to a die plate

where the shape and dimensions are formed, and then through a long cooling line—from 100

DUAL EXTRUDER HYDRAULIC

POWER PACK PLC

THREAD

BASE CAP



to 200 feet long—to further control and stabilize the dimensions. At the end of the line, the

tread is cut according to a specific length and weight for the tire being built.



operation. At present in hydraulic power pack two hydraulic pumps are running continuously


and production cost increases.

So in order to solve this problem we are adding a PLC (Programmable logic

controller), which controls the extruder mouth operations based on pressure. So the two

hydraulic pumps works about 4 hours & hence reduces the power consumption.

In an industry power consumption is very important. For the thread extrusion operation

in the current system it is very energy consuming about 90KWH. We are attempting to

reduce the power consumption by adding a PLC for the control of extruder operation. We

expect a reduction of energy consumption from 90KWH to 20KWH. That is 70KWH is

reduced.

3.5 PROGRAMMABLE LOGIC CONTROLLERS

Programmable logic controllers most widely used industrial process control

technology. A programmable logic controller (PLC) is an industrial grade computer that is

capable of being programmed to perform control functions. The programmable controller has

eliminated much of the hardwiring associated with conventional relay control circuits.

Other benefit it's include.

A programmable logic controller, PLC or programmable controller is a digital

computer used for automation of typically industrial electromechanical processes, such as

control of machinery on factory assembly lines, amusement rides, or light fixtures. PLCs are

used in many industries and machines. PLCs are designed for multiple analogue and digital

inputs and output arrangements, extended temperature ranges, immunity to electrical noise,

and resistance to vibration and impact. Programs to control machine operation are typically

stored in battery-backed-up or non-volatile memory. A PLC is an example of a "hard" real-

time system since output results must be produced in response to input conditions within a

limited time, otherwise unintended operation will result.

http://en.wikipedia.org/wiki/Digital_computer

http://en.wikipedia.org/wiki/Digital_computer

http://en.wikipedia.org/wiki/Automation

http://en.wikipedia.org/wiki/Electromechanical

http://en.wikipedia.org/wiki/Assembly_line

http://en.wikipedia.org/wiki/Amusement_rides

http://en.wikipedia.org/wiki/Light_fixture

http://en.wikipedia.org/wiki/Noise_(electronics)

http://en.wikipedia.org/wiki/Non-volatile_memory

http://en.wikipedia.org/wiki/Real-time_computing

http://en.wikipedia.org/wiki/Real-time_computing



3.5.1 HISTORY OF PLC

Figure 3.3: History of plc

Let’s take a quick look at the history of control systems. As personal computers have

not been around forever, neither have PLCs. In fact, Automation has come a long way from

the beginning.

The earliest automation systems were nothing but directly wired systems. Essentially,

you would turn on a switch, and power would be brought to some output. You turned off the

switch, and power would be removed from the output. This was very similar to your own

household wiring. This required a lot of human intervention. The people pretty much acted

as the PLC.The hardwired system eventually evolved to relay panels. With relay panels, you

could have a series of switches that needed to be activated in order to bring power to the

output. This made the decisions that could be made even more complex, but still required

you to rewire the panel to make changes.

Eventually, PLCs were developed that could be programmed. This allowed the

engineers to easily create much more complex systems than relay panels allowed. It also

allowed changes to be made to the system without having to change any actual wiring. The

PLCs used a programming language called “Relay Ladder Logic”. Relay Ladder Logic

emulated the early relay panels, making it easier for engineers to adapt to the controllers.

Essentially, relay ladder logic used symbols that looked just like the symbols used in relay

drawings. Today, Relay Ladder Logic is often referred to as just “Ladder Logic”, and

encompasses much more than just the old relay symbols. Since PLCs became widespread in



the 70s, they have evolved into complex computer systems capable of advanced

programming algorithms, multiple programming languages, and advanced networking.

Easy programming and installation, high control speed,network compatibility

troubleshooting and testing convenience, and high reliability . The programmable logic

controller is designed for multiple input and output arrangements, extended temperature

ranges, immunity to electrical noise, and resistance to vibration and impact. Programs for the

control and operation of manufacturing process equipment and machinery are typically stored

in battery-backed or nonvolatile memory. A PLC is an example of a real-time system since

the output of the system controlled by the PLC

Depends on the input conditions. The programmable logic controller is, then,

basically a digital computer designed for use in machine control. Unlike a personal computer, it

has been designed to operating the industrial environment and is equipped with special

input/output interfaces and a control programming language. The common abbreviation

used in industry for these devices, PC, can be confusing because it is also the abbreviation

for "personal computer." Therefore, most manufacturers refer to their programmable

controller as a PLC, which stands for "programmable logic controller."Initially the PLC was

used to replace relay logic, but its ever- increasing range of functions means that it is found in

many and more complex applications. Because the structure of a PLC is based on the same

principles as those employed in computer architecture, it is capable not only of performing

relay switching tasks but also of performing other applications such as timing, counting,

calculating.

3.5.2 What Is A Programmable Controller?

A solid state device that controls output devices based on input status and a user

developed program. Originally developed to directly replace relays used for discrete control.

Figure 3.4: PLC



3.5.2.1 INSIDE A PLC

Figure 3.5: Inside PLC

The Central Processing Unit, the CPU, contains an internal program that tells the PLC

how to perform the following functions:

Execute the Control Instructions contained in the User's Programs. This program is

stored in "nonvolatile" memory, meaning that the program will not be lost if power

is removed

Communicate with other devices, which can include I/O Devices, Programming

Devices, Networks, and even other PLCs.

Perform Housekeeping activities such as Communications, Internal Diagnostics,

etc.



3.5.2.1.1 Input Modules

Input modules interface directly to devices such as switches and thermocouples

(thermocouples are devices which can sense temperature)Input modules take electrical

signals such as 24VDC and 4 mA and convert them to digital signals which the PLC

can understand.

Figure 3.6: Input Modules1

Input modules take a signal from a field device and convert it to a signal that

the PLC can understand. Since there are different types of input devices, there is a

wide variety of input cards available, including both digital and analog cards.

Figure 3.7: Input Modules2



3.5.2.1.2 Digital vs. Analog Modules

Digital modules are modules that use only a single bit to represent the state of the

device. For example, a switch is either open or closed. Therefore, the bit is either a 0 (switch

is open) or a 1 (switch is closed).Analog modules are modules that use words to represent the

state of a device. The devices have many states, rather than just 2. For example, the

temperature could be 5, 9, 20, 100, etc degrees. Analog modules use a value, such as 52,

rather than a 0 or 1 to represent the state of the device.

Digital modules use a single bit to represent the state of the device. Digital modules

come in a variety of types and with a variety of input points (typically from 2 to 32). One of

the most popular sizes has 16 input points. Since it takes only 1 bit to represent a state, a 16

point digital module only requires 16 bits of memory in the controller to store the states of all

the points on the module.

Analog modules are modules that use words to represent the state of a device. Analog

modules come in a variety of types and with a variety of input points (typically from 2 to 16).

One of the most popular sizes has 16 input points. Since it takes 1 word to represent a state, a

16 point analog module requires 16 words of memory in the controller to store the states of

all the points on the module. Each word in a PLC takes 16 or 32 bits (depending on the PLC),

therefore it takes 16 or 32 times the amount of PLC memory to store analog points Vs digital

points.

Figure 3.8: Digital vs. Analog Modules



3.5.2.1.3 Output Modules

Output modules interface directly to devices such as motors and lights. Output

modules take digital signals from the PLC and convert them to electrical signals such as

24VDC and 4 mA that field devices can understand.

Figure 3.9: Output Modules1

Output modules take a signal from a PLC and convert it to a signal that a field device

can understand. Since there are different types of output devices, there is a wide variety of

output cards available, including both digital and analog cards

Figure 3.10: Output Modules2



3.5.3 Basic Components of a PLC System

3.5.3.1 Chassis/Backplane

All PLCs need some method of communicating to I/O and communications modules.

There are several different ways in which a PLC can communicate to I/O and communication

modules,modules are installed in the same chassis as the PLC and communicate over the

chassis backplane Modules are designed to “plug” into each other. The interconnecting plugs

form a backplane. There is no chassis Modules are built into the PLC. The modules come

together in one physical block. The backplane in this case is transparent to the user.

3.5.3.2 Power Supply

A power supply is needed to provide power to the PLC and any other modules. Power

supplies come various forms:

Power supply modules that fit into one of the slots in a chassis.

External power supplies that mount to the outside of a chassis.

Stand alone power supplies that connect to the PLC or I/O through a power cable.

Embedded power supplies that come as part of the PLC block.

Figure 3.11: Power Supply



3.5.3.3 Network Interface

Most PLCs have the ability to communicate with other devices. The devices may be a

computer that is running software which can program the PLC, a terminal that lets an

operator enter commands into the PLC, or I/O that is located in a remote location from the

PLC. The PLC will communicate to the other devices through a network interface.

Figure 3.12: Network Interface

3.5.3.4 PLCs as a Part of Control System

The PLC system is the center of a control system, but it is not the entire control

system. There are several other key pieces that must be added to a PLC system to make a

complete control system. Examples are:

Operator terminals

Networks

Distributed I/O devices (I/O that is in a different location then the PLC)

Programming terminals with software

Figure 3.13: PLCs as a Part of Control System



3.5.4 TODAY'S PROGRAMMABLE CONTROLLERS

Many technological advances in the programmable controller industry continue today.

These advances not only affect programmable controller design, but also the philosophical

approach to control system architecture. Changes include both hardware (physical

components) and software (control program) upgrades. The following list describes some recent

PLC hardware enhancements:

3.5.5 PLC AND THE FUTURE

The -future of programmable controllers relies not only on the continuation of new

product developments, but also on the integration of PLCs with other control and factory

management equipment. PLCs are being incorporated, through networks, into computer-

integrated manufacturing (CIM) systems, combining their power and resources with numerical

controls, robots, CAD/ CAM systems, personal computers, management information

systems, and hierarchical computer-based systems. There is no doubt that programmable

controllers will play a substantial role in the factory of the future. New advances in PLC

technology include features Such as better operator interfaces, graphic user interfaces (GUIs),

and more human-oriented man/ machine interfaces (such as voice modules). They also

include the development of interfaces that allow communication with equipment, hardware,

and software that supports artificial intelligence, such as fuzzy logic I/O systems.

Software advances provide better connections between different types of equipment,

using communication standards through widely used networks. New PLC instructions

are developed out of the need to add intelligence to a controller.

Knowledge-based and process learning—type instructions may be introduced to enhance

the capabilities of a system. The user's concept of the flexible manufacturing system (FMS) will

determine the control philosophy of the future. The future will almost certainly continue to

cast programmable controllers as an important player in the factory. Control strategies will be

distributed with "intelligence" instead of being centralized. Super PLCs will be used in

applications requiring complex calculations, network communication, and supervision of

smaller PLCs and machine controllers.



3.5.6 SIEMENS-S71200 PLC

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.

Additional modules are available for communicating over PROFIBUS, GPRS, RS485 or

RS232 networks.

Figure 3.14:SIEMENS-S71200 PLC



Several security features help protect access to both the CPU and the control program:

Every CPU provides password protection that allows you to configure access to the

CPU functions.

You can use "know-how protection" to hide the code within a specific block.

You can use copy protection to bind your program to a specific memory card or

CPU.

3.5.6.1 New features

The following features are new in this release:

● A standard Web server page for performing a CPU firmware update

● The ability to use three PROFIBUS DP CM 1243-5 master modules or three AS-i CM

New modules for the S7-1200

A variety of new modules expand the power of the S7-1200 CPU and provide the

flexibility to meet your automation needs:

● New and improved CPUs:

o New CPU 1215C DC/DC/DC, CPU 1215C DC/DC/Relay, and CPU 1215C

AC/DC/Relay offer 100 Kbytes of work memory, dual Ethernet, and analog

outputs.

o New and improved CPU 1211Cs, CPU 1212Cs, and CPU 1214Cs have faster

processing time, the possibility of 4 PTOs (the CPU 1211C requires a signal

board), increased retentive memory (10 Kbytes), and increased time-of-day hold

up time (20 days).

● New I/O signal module: SM 1231 AI 4 x 16 bit provides higher sample rate and

increased number of bits.

● New battery board (BB 1297) offers long term backup of the real time clock. The BB

1297 is pluggable in the signal board slot of the S7-1200 CPU (firmware 3.0 and later

versions).



3.5.6.2 Power budget

Your CPU has an internal power supply that provides power for the CPU, the signal

modules, signal board and communication modules and for other 24 VDC user power

requirements. The CPU provides a 24 VDC sensor supply that can supply 24 VDC for input

points, for relay coil power on the signal modules, or for other requirements. If your 24 VDC

power requirements exceed the budget of the sensor supply, then you must add an external 24

VDC power supply to your system.

3.5.6.3 Data storage, memory areas and I/O addressing

STEP 7 facilitates symbolic programming. You create symbolic names or "tags" for

the addresses of the data, whether as PLC tags relating to memory addresses and I/O points or

as local variables used within a code block. To use these tags in your user program, simply

enter the tag name for the instruction parameter.

● Global memory: The CPU provides a variety of specialized memory areas, including

inputs (I), outputs (Q) and bit memory (M). This memory is accessible by all code blocks

without restriction

● PLC tag table: You can enter symbolic names in the STEP 7 PLC tag table for specific

memory locations. These tags are global to the STEP 7 program and allow programming

with names that are meaningful for your application.

● Data block (DB): You can include DBs in your user program to store data for the code

blocks. The data stored persists when the execution of the associated code block comes

to an end. A "global" DB stores data that can be used by all code blocks, while an

instance DB stores data for a specific FB and is structured by the parameters for the FB.

● Temp memory: Whenever a code block is called, the operating system of the CPU

allocates the temporary, or local, memory (L) to be used during the execution of the

block. When the execution of the code block finishes, the CPU reallocates the local

memory for the execution of other code blocks

● M memory: Any OB, FC, or FB can access the data in M memory, meaning that the data

is available globally for all of the elements of the user program.

● Temp memory: Access to the data in temp memory is restricted to the OB, FC, or FB

that created or declared the temp memory location. Temp memory locations remain local



and are not shared by different code blocks, even when the code block calls another code

block. For example: When an OB calls an FC, the FC cannot access the temp memory of

the OB that called it.

The CPU provides temp (local) memory for each of the three OB priority groups:

● 16 Kbytes for startup and program cycle, including associated FBs and FCs

● 4 Kbytes for standard interrupt events including FBs and FCs

● 4 Kbytes for error interrupt events including FBs and FCs You access temp memory by

symbolic addressing only.



3.6 FLOW CHART



The figure 3.6 gives an idea about the steps in programming. From this flow chart we

can develop the software part. The different operation performed by the PLC are explained

blow.

1) When emergency stop button is pressed PLC will reset, after this operation the high

pressure and low pressure pumps will switch on.

2) Now the PLC will check whether the extruder head lock operation is performed or not.

3) By using a pressure transmitter/sensor the pressure inside the extruder is continuously

monitored.

4) If the pressure exceeds 300bar or clamp down switch is activated then the hydraulic pumps

are switched off.

5) If the pressure decreases below 290 bar both hydraulic pumps are switched on. And PLC

will again start monitoring the pressure.

6) Else if the extruder head open operation is required the high pressure and low pressure

pumps are switched on.

PLC will continuously execute these operations and monitor the dual extruder.



3.7 PLC ARCHITECTURE

Figure 3.15: PLC Architecture

The central part is the CPU of S71200. The CPU is connected with Digital Input

module, Analog input module and Digital output module .Digital input module is connected

to proximity switch, pushbutton etc. and it is connected towards PLC CPU. Pressure

transmitter output is connected to analog input module and it is connected to the input of PLC

CPU.



3.8 CIRCUIT DIAGRAM

Figure 3.16: Circuit diagram



S71200 CPU and S71200 Digita I/O module(16I&16O) are interconneced.

Inputs are Emergency stop push button ,Control on push button, Hydraulic start push

button,Hydraulic stop push button, Pump1 Overload Relay,Pump2 Overload Relay,Head

open push button,Head close push button,Clamp forward push button, Clamp reverse push

button,Head lock push button, Head unlock pushbutton are connected to CPU va a Diagital

I/O interface.

Outputs are Control ON lamp,Pump1 Contactor,Pump2 Contactor,Head open solinoid

valve, Head close solinoid valve,Clamp close solinoid valve,Clamp open solinoid valve,Head

lock solinoid valve,Head unlock solinoid valve,High pressure solinoid valve,Lubrication

solinoid valve,Alarm light,High pressure ON lamp,Pump1 ON lamp,Pump 2 on lamp. are

connected from CPU to Diagital I/O interface.

3.8.1 SIEMENS S71200 ANALOG I/O MODULE

Figure 3.17: SIEMENS S71200 Analog I/O module

Siemens S7 1200 Analog I/O module act as an interface between analog device and

Siemens S7 1200 CPU. Here pressure in the extruder is to be monitored. So we are using a



Pressure transmitter. By using a pressure transmitter we are able to obtain the pressure in the

range (4-400)bar and produces (4-20) mA current.

3.8.2 POWER DISTRIBUTION NETWORK

Figure 3.18: Power distribution network

For both two pumps 3.7KW and 2.2KW, three phase supply is needed it is connected via

MPCBs . For 3.7KW pump we use (5-8) amp MPCB and for 2.2KW pump (4-6.5) amp MPCB is

used. Then connected to the coils of the corresponding pumps.

Then a two phase supply is taken via 2amp MCB, by using a step down transformer

(415/110v) the voltage level is reduced to 110V. This voltage is used for energizing the solenoid

valves and also applied to 24v DC power supply, constant 24v is produced and it is used for the

working of PLC and other input /output devices.



3.9 SOLENOID VALVE

A solenoid valve is an electromechanically operated valve. The valve is controlled by

an electric current through a solenoid: in the case of a two-port valve the flow is switched on

or off; in the case of a three-port valve, the outflow is switched between the two outlet ports.

Multiple solenoid valves can be placed together on a manifold.

Solenoid valves are the most frequently used control elements in fluidics. Their tasks

are to shut off, release, dose, distribute or mix fluids. They are found in many application

areas. Solenoids offer fast and safe switching, high reliability, long service life, good medium

compatibility of the materials used, low control power and compact design.

The illustration below depicts the basic components of a solenoid valve. The valve

shown in the picture is a normally-closed, direct-acting valve. This type of solenoid valve has

the most simple and easy to understand principle of operation.

Figure 3.19: Solenoid valve

1. Valve Body 4. Coil / Solenoid 7. Plunger

2. Inlet Port 5. Coil Windings 8. Spring

3. Outlet Port 6. Lead Wires 9. Orifice

http://en.wikipedia.org/wiki/Electromechanical

http://en.wikipedia.org/wiki/Valve

http://en.wikipedia.org/wiki/Electric_current

http://en.wikipedia.org/wiki/Solenoid

http://en.wikipedia.org/wiki/Hydraulic_manifold

http://en.wikipedia.org/wiki/Fluidics

http://www.solenoid-valve-info.com/solenoid-valve-terminology.html#normally_closed

http://www.solenoid-valve-info.com/solenoid-valve-terminology.html#direct_acting



The media controlled by the solenoid valve enters the valve through theinlet port (Part

2 in the illustration above). The media must flow through the orifice (9) before continuing

into the outlet port (3). The orifice is closed and opened by the plunger (7) The valve pictured

above is a normally-closed solenoid valve. Normally-closed valves use a spring (8) which

presses the plunger tip against the opening of the orifice. The sealing material at the tip of the

plunger keeps the media from entering the orifice, until the plunger is lifted up by an

electromagnetic field created by the coil.

3.10 SOFTWARE DESCRIPTION

3.10.1 System requirements

To install the STEP 7 software on a PC running Windows XP or Windows 7 operating

system, you must log in with Administrator privileges.

Hardware/software Requirements

Processor type Pentium M, 1.6 GHz or similar

RAM 1 GB

Available hard disk space 2 GB on system drive C:\

Operating systems • Windows XP Professional SP3

• Windows 2003 Server R2 StdE SP2

• Windows 7 Home Premium (STEP 7 Basic only, not supported for STEP 7

Professional)

• Windows 7 (Professional, Enterprise, Ultimate)

• Windows 2008 Server StdE R2

Table 3.1 System requirements

Graphics card 32 MB RAM 24-bit color depth

Screen resolution 1024 x 768

Network 20 Mbit/s Ethernet or faster

Optical drive DVD-ROM

http://www.solenoid-valve-info.com/solenoid-valve-terminology.html#port_inlet

http://www.solenoid-valve-info.com/solenoid-valve-terminology.html#media

http://www.solenoid-valve-info.com/solenoid-valve-terminology.html#orifice

http://www.solenoid-valve-info.com/solenoid-valve-terminology.html#port_outlet

http://www.solenoid-valve-info.com/solenoid-valve-terminology.html#plunger

http://www.solenoid-valve-info.com/solenoid-valve-terminology.html#valve_coil



3.10.2 Different views to make the work easier

STEP 7 provides a user-friendly environment to develop controller logic, configure

HMI visualization, and setup network communication. To help increase your productivity,

STEP 7 provides two different views of the project: a task-oriented set of portals that are

organized on the functionality of the tools (Portal view), or a project-oriented view of the

elements within the project (Project view). Choose which view helps you work most

efficiently. With a single click, you can toggle between the Portal view and the Project view.

Figure 3.20: Portal view & Project view

With all of these components in one place, you have easy access to every aspect of

your project. For example, the inspector window shows the properties and information for the

object that you have selected in the work area. As you select different objects, the inspector

window displays the properties that you can configure. The inspector window includes tabs

that allow you to see diagnostic information and other messages.

Portal view

① Portals for the different tasks

② Tasks for the selected portal

③ Selection panel for the selected action

④ Changes to the Project view

Project view

① Menus and toolbar

② Project navigator

③ Work area

④ Task cards

⑤ Inspector window

⑥ Changes to the Portal view

⑦ Editor bar



By showing all of the editors that are open, the editor bar helps you work more

quickly and efficiently. To toggle between the open editors, simply click the different editor.

You can also arrange two editors to appear together, arranged either vertically or

horizontally. This feature allows you to drag and drop between editors.

3.10.3 Easy-to-use tools

3.10.3.1 Inserting instructions in to your user program

STEP 7 provides task cards that contain the instructions for your program. The

instructions are grouped according to function. To create your program, you drag instructions

from the task card onto a network.

3.10.3.2Changing the operating mode of the CPU

The CPU does not have a physical switch for changing the operating mode

(STOP or RUN).Use the "Start CPU" and "Stop CPU" toolbar buttons to change the

operating mode of the CPU. When you configure the CPU in the device configuration, you

configure the start-up behavior in the properties of the CPU.

The "Online and diagnostics" portal also provides an operator panel for changing the

operating mode of the online CPU. To use the CPU operator panel, you must be connected

online to the CPU. The "Online tools" task card displays an operator panel that shows the

operating mode of the online CPU. The operator panel also allows you to change the

operating mode of the online CPU.

Use the button on the operator panel to change the operating mode (STOP or RUN).

The operator panel also provides an MRES button for resetting the memory. The color of the

RUN/STOP indicator shows the current operating mode of the CPU. Yellow indicates STOP

mode, and green indicates RUN mode.



3.10.3.3 Dragging and dropping between editors

To help you perform tasks quickly and easily, STEP 7 allows you to drag and drop

elements from one editor to another. For example, you can drag an input from the CPU to the

address of an instruction in your user program. You must zoom in at least 200% to select the

inputs or outputs of the CPU. Notice that the tag names are displayed not only in the PLC tag

table, but also are displayed on the CPU

Figure 3.21: Dragging and dropping

To display two editors at one time, use the “Split editor" menu commands or buttons in the

toolbar.

To toggle between the editors that have been opened, click the icons in the editor bar.



CHAPTER 4

IMPLEMENTATION

4.1 SIEMENS-S71200 PLC

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.

4.2 PROCEDURE FOR PROGRAMMING

For the development of project we need “Siemens Totally integrated automation”

software. The different steps in programming are as follows

1) Creating new project

Figure 4.1: Creating new project

Project name,Path to save the data,author’s name and other comments are inserted.



2) Configuring Project

Figure 4.2: Configuring Project

A new window will appear and we can configure the device, PLC ladder diagram etc can

be added.

3) Inserting &configuring CPU

Figure 4.3: Inserting &configuring CPU1



You create your device configuration by inserting a CPU into your project. Be sure

you insert the correct model and firmware version from the list. Selecting the CPU from the

"Add new device" dialog creates the rack and CPU.



Now by selecting the device change the Input address and output address.

For input: Start address is 0, End address is 0.

For output: Start address is 0, End address is 0.



Now select the general tab and drop down startup menu:

In the “startup after POWER ON” menu select Warm restart-RUN.

Now select system and clock memory

Enable the use of system memory byte.

4) Inserting & configuring Digital I/O module and Analog I/O module

Figure 4.6: Inserting & configuring Digital I/O module and Analog I/O module 1

From the filter window select (6ES7223-1BL32-0XBO) which is a 16 bit Digital I/O

module.24v is the supply voltage .Now by selecting the device change the Input address and

output address.

For input: Start address is 8,End address is9.

For output:Start address is 8,End address is9.



Figure 4.7: Inserting & configuring Digital I/O module and Analog I/O module 2

From the filter window select (6ES7224-4HE30-0XBO) which is a 13 bit Analog I/O

module.24v is the supply voltage. Now by selecting the device change the Input address and

output address.

For input: Start address is 10, End address is 17.

For output: Start address is 10, End address is 13.

5) Inserting tags

Figure 4.8: Inserting tags



Different inputs and outputs required are assigned with tags. Input is represented with

I and output with Q.

6) Ladder diagram development

Figure 4.9: Ladder diagram development

Programming is done by using ladder diagram ladder diagram is developed based on the

requirements of the system.

4.3 INSTRUCTIONS USED

4.3.1 Timers

You use the timer instructions to create programmed time delays. The number of

timers that you can use in your user program is limited only by the amount of memory in the

CPU. Each timer uses a 16 byte IEC_Timer data type DB structure to store timer data that is

specified at the top of the box or coil instruction. STEP 7 automatically creates the DB when

you insert the instruction.



LAD / FBD boxes LAD coils SCL Description

"IEC_Timer_0_DB".TP( IN:=_bool_in_, PT:=_time_in_, Q=>_bool_out_, ET=>_time_out_);

The TP timer generates a pulse with a preset width

time.

Table 4.1: Timers

4.3.2 Set and reset instructions

Set and Reset 1 bit

LAD FBD SCL Description

Not available When S (Set) is activated, then the data value at the OUT

address is set to 1. When S is not activated, OUT is not changed.

Not available When R (Reset) is activated, then the data value at the OUT

address is set to 0. When R is not activated, OUT is not

changed.

Table 4.2: Set and reset instructions

4.3.3 Calculate instruction

LAD / FBD SCL Description

Use the

standard SCL

math

expressions to

create the

equation.

The CALCULATE instruction lets you create a math function that operates on inputs (IN1, IN2, .. INn) and produces the result at OUT, according to the equation that you define.

• Select a data type first. All inputs and the output must be the same data type.

• To add another input, click the icon at the last input.

Table 4.3: Calculate instruction

4.3.4 Bit logic contacts and coils

LAD and FBD are very effective for handling Boolean logic. While SCL is especially

effective for complex mathematical computation and for project control structures, you can

use SCL for Boolean logic.



LAD contacts

LAD SCL Description

IF in THEN Statement; ELSE Statement; END_IF;

Normally open and normally closed contacts: You can connect contacts to other contacts and create your own combination logic. If the input bit you specify uses memory identifier I (input) or Q (output), then the bit value is read from the process-image register. The physical contact signals in your control process are wired to I terminals on the PLC. The CPU scans the wired input signals and continuously updates the corresponding state values in the process-image input register. You can specify an immediate read of a physical input using ":P" following

the I offset (example: "%I3.4:P"). For an immediate read, the bit data values

are read directly from the physical input instead of the process image. An

immediate read does not update the process image.

IF NOT (in) THEN Statement; ELSE Statement; END_IF;

Table 4.4: Bit logic contacts and coils

Parameter Data type Description

IN Bool Assigned bit

Table 4.5: Data types for the parameters

● The Normally Open contact is closed (ON) when the assigned bit value is equal to 1.

● The Normally Closed contact is closed (ON) when the assigned bit value is equal to 0.

● Contacts connected in series create AND logic networks.

● Contacts connected in parallel create OR logic networks.

4.3.5 Convert

CONV instruction

LAD / FBD SCL Description

out := <data type in>_TO_<data type out>(in); Converts a data element from one

data type to another data type.

Table 4.6: Convert (CONV) instruction



CHAPTER 5

RESULTS

In a dual extruder there are two pumps, Power of pump 1 is 3.7Kw and Power of

pump 2 is 2.2Kw.

Total Power=3.7+2.2= 5.9Kw

BEFORE PLC

Time taken by two motors to work=18 hours.

Average load=85%.

Power consumption per day=5.9x.85x18=90KwH.

Rupees per unit=₹ 4.9

Energy Bill=4.9x90x30=₹ 13230

AFTER PLC

Time taken by two motors to work=4 hours.

Average load=85%.

Power consumption per day=5.9x.85x4=20KwH.

Rupees per unit=₹ 4.9

Energy Bill=4.9x20x30=₹ 2940

Addition of PLC can save up to 70Kw (₹ 10290 / MONTH)



ADVANTAGES

• Wastage of power can be reduced to a great extent.

• PLCs are easily programmed and have an easily understood programming language.

• Less and simple wiring.

• Increased Reliability.

• More Flexibility.

• Lower Cost.

• Faster Response.

• Easier to troubleshoot.

• Remote control capability.

• Communication Capability.

• Handles much more complicated systems.



CHAPTER 6

CONCLUSION

The ultimate goal of our project is to reduce the amount of energy consumption. In

the old system there is no certain device to control the Dual Extruder and also it consume

more energy. In the old system which consume 90KWH per day. But after adding PLC it is

reduced to 20KWH per day .Thus saving about 70KWH per day, by the addition of PLC the

energy wastage is reduced to a great extent. PLC automation can make a good impact in

industrial sector.



CHAPTER 7

FUTURE SCOPE

PLC's are used in much "real world application". If there is industry present

chances are good that there is a PLC present. If you are involved in matching, packing, material

handling, automated assembly or countless other industries you are probably already using

them. If you are not, you are wasting time and money. Almost any application that needs

some type of electrical control has need for a PLC. The main advantages of the PLC

system are efficiency, reliability, time grain, durability etc. There is a huge scope for

converting the machine process to fully automated with PLC. Production rate and quality of

the product can be improved by integrating more input parameters.



APPENDICES

1)DEVICE OVERVIEW



2)PLC TAGS



3)PROGRAM BLOCKS



REFERENCES

www.emtindia.net/process/tyre/pdf/TyreManufactureProcess0.pdf

http://www.enotes.com/how-products-encyclopedia/tir

http://en.wikipedia.org/wiki/Tire_manufacturing

http://www.bridgestone.co.in/tyre/tyrecare/safedriving.as

http://electrical-engineering-portal.com/14-energy-efficiency-improvement-

opportunities-in-pumping-systems

www.siemens.com

Tyre manufacturing process Seminar report from IIT-Bombay (2012)

http://www.enotes.com/how-products-encyclopedia/tir

http://en.wikipedia.org/wiki/Tire_manufacturing

http://www.bridgestone.co.in/tyre/tyrecare/safedriving.as



http://www.siemens.com/

automation of dual extruder hydraulic power pack full report 2015 done at apollo tyres kalamassery...

Engineering

dean of engineering

technology manjaly

hydraulic cylinders

valuable guidance

valuable support

project work

mannam p

ajay p raj reg