Precise Control Automation

The company in which we are pursuing our

project is Precise Control Automation
A customer-oriented company
Gold channel partner of ABB
Provides wide array of Engineering Solutions
and Services
Carries out its business primarily in the field of
electrical systems and industrial automation
PROBLEM SUMMARY
In todays world, time consuming and precision
in any work is given at most importance.
Cloth cutting through manual process is much
more time consuming and less precise as
compared to automated cloth cutting machine
using PLC.
Also, design of specific pattern as per the
requirement can be made on the cloth like the
design of a shirt, jeans, etc. with the help of
appropriate coding and setup using PLC.

Time Line
Month Work
July Company Survey
Definition
August PLC Basis
September Project Equipments
and Availability
October Structure Idea
November Programming
January Mechanical Model
February-March Real Time Debugging
Block Diagram
Basic Idea of Model
PLC
(Programmable Logic Controllers)

An industrial computer used to monitor
inputs, and depending upon their state make
decisions based on its program or logic, to
control its outputs to automate a machine or
a process
They are capable of storing instructions, such
as sequencing, timing, counting, arithmetic,
data manipulation, and communication, to
control industrial machines and processes.







Diagram of a PLC application


Hardware Components of a PLC
System
Processor unit (CPU)
Memory
Input/output
Power supply unit
Programming device
And other devices

PLC Operations
Input Relays
Internal utility Relays
Timers
Counters
Output Relays
Data Storage
PLCs cost > Microcontrollers cost
Then also Why use of PLC ???

Our project can also be accomplished with the
help of controller but to expand this project to
the industry level, PLC is more suitable.


In an industry, there would be many machines
assigned the same task of cutting the cloth. With
the help of PC, more than one PLC can be
controlled using some software. This concept is
called as a DSP(digital system process).

Also, if the engineer wishes to design the cloth
instead of simply cutting the cloth than only
programming is to be changed in PLC through a
Computer connected to PLC. If the same task is
to accomplished with the help of controller than
the controller from all machines needs to be
taken out and the program would be inserted
externally through its kit which would be tedious
and time consuming.

Components used in our Model
AC 500 PLC of ABB
Motors
Rotary Encoder
Sheets of polished sunmica
Rollers
Cutter
Conveyer Belt

PLC - AC 500

AC500 is nothing but the PLC which is
manufactured by ABB
In this category also there are so many PLCs
and we can choose any according to our
requirement
As student purpose, Precise Automation
provides AC500 PM564-T echo PLC which A
type of AC500 only


AC500 has following main features
It can be programmed in five different
languages
provides an LCD display
an operator keypad
an SD card slot
two integrated serial interfaces
can be expandable by up to seven local I/O
modules

CODESYS
Codesys stands for Controlled Development
System.
Codesys is a complete development
environment for ABB PLC.
Codesys puts a simple approach to the
powerful IEC language at the disposal of the
PLC programmer. Use of the editors and
debugging functions is based upon the proven
development program environments of
advanced programming languages (such as
Visual C++).

Rotary Encoder
A rotary encoder is an electro-
mechanical device that converts
the angular position or motion of a shaft or axle
to an analog or digital code

There are two modes of operating :
absolute
incremental (relative)

Incremental Mode
An rotary encoder has three outputs namely,
A,B & C
A and B output changes as follows as per the
motion of the motor




Output C is called the index, it gives a positive
pulse at each turn of the encoder shaft
Phase Shift A B
0 0 0
90 0 1
180 1 1
270 1 0
Polished Sunmica
Two sheets of polished
sunmica as shown in the
model on both sides on
which the cloth would
flow and on which
motors & other types of mechanism would be
set up



Roller
Two rollers would be used, one on each Sunmica
One end of 1
st
roller is connected to motor and
other end is connected to rotary encoder
One end of 2
nd
roller is connected to other motor
and other end is left free
The radius of the 1
st
roller would be kept such
that 0.2m cloth would pass through it in one
revolution of the roller
The 2
nd
roller is connected with a
motor just for the purpose of
increasing the tensile strength for
cutting and throwing out the cloth
which is already been cut

Programming
There are 6 type of programming language.
IL-instruction flow diagram
LD-ladder diagram
FBD-function block diagram
SFC- Sequence function chart
ST-structural text
CFC- Continuous function chart

Function block diagram
Since we are using ABB PLC, we are using
codesys software for programing
We are going to use Function block diagram
language
There are inbuilt functions already available in
library in form of box which can be directly
used
We only need to provide input and output and
interconnection of different blocks can be
done
DIVIDER
INPUT 2
0.2 m
NO OF COUNT
FOR ROLLER
input1 = No of quantity
input 2 =Length of cloth
The output will give us the number of count to
be rolled by the roller to cut specified amount
of cloth
The roller-1 will be connected to motor-1 and
roller-2 will be connected to another motor-2
Comparator
Output of
rotatory
encoder
NO OF
COUNT FOR
ROLLER
EQUAL
NOT-
EQUAL
STOP
motor-1
START
The rotatory encoder will give one pulse output if roller
completes one whole rotation and so the comparator will
compare the rotatory encoder output and number of
count for roller as shown in earlier block.
If they are same then motor-1 will stop and if not the
motor will rotate till it becomes equal.
Comparator
START
EQUAL
Motor-1
Stop
Whenever Motor-1 will start motor -2 will start
simultaneously
Equal
Back to
comparing output
of rotatory
encoder
Not Equal
Comparator
START
Motor-1
Motor-2
Starts
At this stage the no. of input and rotatory encoder
count will be equal, so motor-1 is stopped and now
we need to stop motor-2 simultaneously so we use
NAND gate.
Motor-2
Stops
Equal
Not-
Equal
TIMER
Start
T# 0.5 s
Motor-2
starts
We will start the motor-2 again for 0.5 sec to stretch
the cloth so that it can be cut easily.
TIMER
START
T# X s
Cutter
We will calculate the time that cutter takes to cut one
piece of cloth and suppose it is X sec, then we will
start the motor associated with the cutter for X sec.
TIMER
START
T# 1 s
Motor-2
To throw the cloth which is been already cut, we
need to a rotate the motor-2 for 1 sec again
Comparator
Cutter
Counter
Input-1
Equal
RESET
And STOP
Not-
Equal
Start loop
again
No of quantity =input1
We will use the increment counter
As the cutter goes forward and comes back, the counter gets
incremented.
Suppose the counter value is 2 that means the two pieces of cloth
has been already cut. Now if that counter value and the given input
quantity value will be equal then all the inputs gets RESET and if
not equal then whole loop gets repeated.
Thank You