TYRE MANUFACTURING
• COMPOUND MIXING.
• EXTRUSION.
• CALENDERING.
• PLY CUTTING (BIAS CUTTING).
• TYRE BUILDING OR TYRE ASSEMBLING.
• TYRE CURING.
• POST CURE INFLATION.
• INSPECTION.
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EXTRUDER
Types
• Ram Extruder.
• Gear Pump Extruder.
• Single Screw Extruder.
Dual Extruder
Power of motor 1= 3.7Kw.
Power of motor 2=2.2Kw.
Total Power=3.7+2.2= 5.9Kw.5
THREAD EXTRUSION BEFORE ADDING PLC
DUAL EXTRUDER
HYDRAULIC POWER PACK
THREAD
BASE CAP
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• No pressure sensing.
• Energy wastage.
• No control in the extrusion.
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=Rs.13230
SIEMENS-S71200 PLC
• The S7-1200 series is a line of programmable logic controllers (PLCs).
• Can control a variety of automation applications.
• Compact design.
• low cost, and a powerful instruction set.
• A perfect solution for controlling a wide variety of applications.
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• 1200 models and the Windows-based programming tool give you the flexibility you need to solve your automation problems.
• The CPU combines a
Microprocessor
Integrated power supply
Input and Output circuits
Built-in PROFINET (port for communication over a network)
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Continued..
DIFFERENT PROGRAMMING TECHNIQUES
• Function Block DiagramPictorial method of programming
Blocks for each function that show the inputs and outputs
• Instruction ListComplicated method
Assembly language
• Ladder DiagramLooks like a ladder with the inputs and outputs
Diagram looks like a wiring schematic
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PROCEDURE FOR PROGRAMMING
• Creating new project.
• Inserting &configuring CPU.
• Inserting & configuring Digital I/O module.
• Inserting & configuring Analog I/O module.
• Inserting tags .
• Ladder diagram Development.
• Program simulation.
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SIEMENS S71200 CPU
Digital I/O Module
Analog module
MPCB
24 V POWER SUPPLY
440V-110 V TRANSFORMER
Relays
Contactor
MCB and ELCB
Pump 1 Pump 2 Contactor
RESULTS
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=Rs.2940
• Addition of PLC can save upto 70Kw (Rs.10290 / MONTH)
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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.25
CONCLUSION
OLD SYSTEM
• No certain device to control the Dual Extruder.
• consume 90KWH per day.
AFTER ADDING PLC
• consume 20KWH per day .
• saving about 70KWH per day
• PLC automation can make a good impact in industrial sector.
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