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Dairy Factory Automation Project Guide

The document outlines a project for automating a dairy factory, detailing learning outcomes related to PLC design, implementation, and project management. It specifies the subsystems to be automated, including personnel attendance, raw materials management, mixing, molding, baking, packaging, and emergency protocols. Expected deliverables include system schematics, block diagrams, encoding tables, and ladder diagrams, along with required skills for successful completion.

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111 views3 pages

Dairy Factory Automation Project Guide

The document outlines a project for automating a dairy factory, detailing learning outcomes related to PLC design, implementation, and project management. It specifies the subsystems to be automated, including personnel attendance, raw materials management, mixing, molding, baking, packaging, and emergency protocols. Expected deliverables include system schematics, block diagrams, encoding tables, and ladder diagrams, along with required skills for successful completion.

Uploaded by

dardhahl2s
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

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Project Description
Learning Outcomes:
Upon the accomplishment of the project that follows the student should be able to:

LO 1 Design logic circuits and Boolean functions for different applications.


LO 2 Distinguish main PLC components (inputs, outputs, processor, memory, power
supply).
LO 3 Explain the functions of PLC components in terms of hardware and ladder logic.
LO 4 Design and implement an original ladder logic diagram dealing with the main
PLC components.
LO 5 Solve, illustrate, and complete algorithms, flowcharts, and diagrams that meet
certain practical/industrial requirements.
LO 6 Build PLC programs, evaluate and compare them according to alternative
solutions.
LO 7 Document the proposed solutions towards project achievement with the relevant
verification and validation.
LO 8 Maintain professional conduct as required in real-life engineering practice.
LO 9 Develop project management skills individually and within a team.

To prove the accomplishment of all the pre-listed learning outcomes, you are requested to
submit all deliverables, workbook, codes, flowcharts, testing and user manual as per the
detailed assessment plan in the unit outline.
Please refer to the unit outline for more details about the submission of every assessment item.

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The Dairy Factory Automation System
Context:

You have been employed by a private dairy products manufacturer such as Yasmin Farms to automate
their manufacturing process. The factory is composed of the following subsystems which require
automation.

Normal operation:

This is when there are no emergencies, and the factory operates under normal conditions.

• Personnel attendance
o Keep track of the number of personnel inside the factory
o Do not allow more than 42 personnel inside the factory at a time, unless he/she is a
supervisor with a special pass.
o Allow entry of personnel only from 6:30 am - 9 am, unless they have a special pass.
• Raw materials warehouse
o Keeping track of raw materials such as water, skimmed and whole milk, sugar,
flavoring materials, etc. and trigger order calls if stocks fall below certain levels via a
warning message.
o Preserve raw material in certain conditions (temperature, moisture, etc.) to avoid
spoiling and contamination such as keeping the milk between 33°F to 38°F.
• Mixing stage
o Raw materials must be prepared and combined with certain ratios (you may use your
own recipe)
o The compounds must be mixed around 37°F temperature for 50 secs.
• Molding and cutting stage
o Cheese and ice-cream are molded and cut into required shapes.
• Baking stage
o Baking is performed according to the type of product that is produced (temperature and
duration of baking may vary according to the type)
• Packaging
o Every 8 pieces are packed into one pack, then every 18 packs are packed into one box.
Then every 64 boxes on a crate then stockpiled inside the shipping warehouse.
• Shipping
o If the number of boxes inside the factory matches the number of boxes ordered, a
shipping order is triggered by the delivery department.

Operation under emergency:

• In case of fire, or any other emergency the proper shutdown and evacuation protocol must be
followed including:
o Stopping the operation of the factory
o Turning on an alarm siren and light
o Opening all gates for evacuation
o Alarming the fire department and police

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Special provisions:

The system must also provide for the following functionalities:

• All subsystems are interconnected through automated conveyor belts.


• Information between various subsystems is exchanged through proper input/output signals.
• The system must run continuously and in a pipelined fashion to maximize production.
• The system must be capable of faulty and emergency detection.
• The system must be flexible for a different recipe (think about the mixture ratios, mixing times,
freezing, etc.).

Expected output:

Your final solution must contain the following components:

1. System schematic briefly showing different subsystems of the factory and how they are
interconnected.
2. Block diagram of all subsystems clearly identifying the following:
a. External input/outputs of the subsystem (e.g. the required sensors, actuators, lights,
motors, heaters, etc.)
b. Internal input/outputs of the subsystem that are used to keep track of the status of the
system.
c. Any advanced computational blocks that are used to implement the subsystem (e.g.
timers, counters, comparators, etc.)
3. An encoding table for each subsystem describing the encoding scheme for all external
input/outs (e.g. what does it mean if the start switch is 1, does it mean it is ON?)
4. Ladder diagram of every subsystem, and its explanation
5. The complete ladder diagram after assembling all subsystems together.

Expected skills:

• Identification of system inputs and outputs


• Selection of appropriate external devices such as sensors and actuators
• Conversion of verbal description of a system into logical expressions
• Conversion of logical expressions into digital circuits
• Selection and application of proper PLC programming components
• Implementation of the system using ladder logic
• Testing and debugging of the ladder diagram
• Documentation and presentation
• Project and time management

[Link]

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Common questions

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Emergency shutdown and evacuation protocols can be implemented by programming the PLC to detect emergency triggers, such as smoke or heat sensors. Once detected, the PLC can automatically stop all machinery, activate alarm sirens and lights, open all exit gates, and alert external emergency services. This ensures a rapid and coordinated response to emergencies, minimizing risks to personnel and equipment .

Real-time monitoring ensures that each component of the dairy manufacturing process is functioning within the required parameters, preventing issues like spoilage of raw materials or inefficient production cycles. Pipelined processing allows different stages of production to operate simultaneously, minimizing idle time between stages and significantly boosting overall efficiency by ensuring continuous operation and reducing the cycle time for each product .

Flexibility is achieved through the PLC's ability to modify processing parameters such as ingredient ratios, mixing times, and temperatures based on different inputs. The PLC programs can be updated or reconfigured to accommodate new recipes, allowing the dairy factory to produce various products without extensive manual reprogramming, thus enhancing adaptability to market demands .

Sensors play a crucial role in continuously monitoring the environmental conditions such as temperature and humidity to ensure they remain within safe ranges (e.g., milk storage between 33°F to 38°F). Actuators respond to sensor inputs by adjusting heating or cooling mechanisms to maintain these conditions. This integrated system helps prevent spoilage and contamination of raw materials, ensuring consistent product quality .

Challenges include synchronizing the operation of various subsystems to prevent bottlenecks, ensuring the reliability of conveyor components, and maintaining seamless data exchange between subsystems. Solutions involve using well-programmed PLCs to orchestrate timing and sequencing, implementing robust communication protocols for data integrity, and regular maintenance checks to ensure consistent performance of conveyor systems, thereby optimizing the assembly-line efficiency .

The main functions of a PLC include managing inputs and outputs, processing logical operations, controlling timing and sequencing, and ensuring safety protocols are followed. In a dairy factory, the PLC manages the automation of processes like personnel attendance, mixing raw materials at precise temperatures, molding, baking, packaging, and triggering shipping orders when boxes are ready. It also handles emergency operations such as stopping factory operations and initiating evacuations in case of fire .

Successful implementation requires skills such as task delegation, time management, effective communication, problem-solving, and adaptability. These skills ensure that the project stays on schedule, all team members understand their roles, and any issues are addressed promptly. Additionally, maintaining documentation for verification and validation is crucial for proving project outcomes and meeting stakeholder requirements .

Flowcharts and diagrams are crucial as they provide a visual representation of the process logic and flow within the PLC program. They help in outlining the operations, necessary inputs and outputs, and sequence of tasks. This aids in effective planning, debugging, and communication between team members, ensuring that all components of the automated system are well organized and aligned with operational requirements .

The PLC system manages personnel attendance by tracking the number of personnel and ensuring it does not exceed 42 individuals, unless a supervisor with a special pass enters. It also restricts entry to specific hours (6:30 am - 9 am) unless special permission is provided, ensuring efficient management and maintaining safety protocols within the factory setting .

Ladder logic serves as a graphical programming language where symbols represent the control logic needed for operations. It effectively simulates relay logic, allowing control over various stages like mixing, molding, baking, and packaging via interconnections and signal exchanges between subsystems. This ensures that processes proceed in a coordinated manner according to predefined sequences and triggers, thus automating the dairy manufacturing process efficiently .

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