Control System Design using PLC and SCADA (CV Project)

Project Title: Basic Automation Control System using Allen-Bradley PLC and SCADA

Summary: Built a simple automation project using an Allen-Bradley PLC and SCADA to demonstrate core concepts of industrial
control. The project automated a small conveyor and filling system, showing how inputs from sensors can control outputs like
motors and valves, and how the process can be monitored on a SCADA screen.

What I Did
• PLC Programming (Ladder Logic):
• Programmed using RSLogix/Studio 5000 for Allen-Bradley PLC.
• Created logic to start/stop a conveyor using push buttons.
• Added a sensor to detect a bottle and stop the conveyor for filling.
• Activated a valve for a few seconds to fill the bottle, then restarted the conveyor.

• Implemented safety interlocks using an emergency stop and tank level switches.

• SCADA/HMI:

• Used FactoryTalk View to design a simple HMI screen.

• Displayed conveyor, valve, and tank status.
• Added operator controls (Start, Stop, Reset) and alarms (overfill, emergency stop).

Tools Used
• PLC Software: RSLogix/Studio 5000 (for Allen-Bradley PLC programming).
• SCADA/HMI: FactoryTalk View (for visualization and control).
• Simulator: Allen-Bradley emulator (RSLogix Emulate 5000) to test logic.

Outcome
• Successfully created a working simulation of a conveyor and filling process using Allen-Bradley PLC.
• Demonstrated knowledge of ladder logic programming, sensors/actuators, and SCADA visualization.
• Showed ability to connect PLC logic with SCADA for real-time monitoring and control.
✅ This project is simple, practical, and interview-friendly, clearly showing understanding of AllenBradley PLC programming
and SCADA basics.
ECE Interview Project Portfolio

Project 1: Ladder Logic Control System

This project demonstrates a fundamental understanding of programmable logic controllers (PLCs) and industrial automation.

1.1 Ladder Logic Basics

Ladder logic is a programming language that mimics a physical electrical relay circuit. It's the most common programming
language for PLCs and is used extensively in manufacturing and industrial automation.

• What is a PLC? A Programmable Logic Controller is a ruggedized industrial computer that controls a machine or
process. Unlike a regular computer, it is designed for multiple inputs and output arrangements, extended
temperature ranges, immunity to electrical noise, and resistance to vibration and impact.

• The PLC Scan Cycle: A PLC operates in a continuous loop called a scan cycle. Understanding this is crucial.

1. Read Inputs: The PLC reads the current state of all its inputs (e.g., buttons, sensors).

2. Execute Logic: It then executes the ladder logic program, solving the rungs from top to bottom.

3. Update Outputs: Finally, it updates the state of the outputs (e.g., motors, lights) based on the results of
the logic.

• Rungs: Horizontal lines representing a single logical operation.

• Inputs (Contacts):

o Examine If Closed (XIC): | | - Normally Open (NO) contact. This instruction is true when the input is ON.
In a physical circuit, this would be a button that closes a circuit when pressed.

o Examine If Open (XIO): |/| - Normally Closed (NC) contact. This instruction is true when the input is OFF.
In a physical circuit, this would be a button that breaks a circuit when pressed.

• Outputs (Coils):

o Output Energize (OTE): ( ) - This instruction turns on a physical output when the rung logic is true. An
output could be a motor, a light, a valve, or any other device.

• Logic:

o AND Logic: Contacts in series; all conditions must be true for the output to be energized.

o OR Logic: Contacts in parallel; only one of the parallel conditions needs to be true for the output to be
energized.

1.2 PLC Implementation in RSLogix Micro Starter Lite

Here is how the diagram's logic is implemented in a PLC program. The addresses (e.g., I:0/0) refer to the physical input and
output terminals on the PLC.
 • Conveyor Control Rung:

o Logic: The conveyor runs when the Start button is pressed. A sealing contact keeps it running until the Stop
button is pressed.

o Implementation: An XIC Start (e.g., I:0/0) and an XIO Stop (e.g., I:0/1) are placed in series. An OTE
Conveyor (e.g., O:0/0) is at the end of the rung. A parallel branch is used to "seal in" the circuit. This branch
contains an XIC instruction with the same address as the Conveyor output (O:0/0).

• Valve Control Rung:

o Logic: The valve is energized only when both the Sensor and the Conveyor are active.

o Implementation: An XIC Sensor (e.g., I:0/2) and an XIC Conveyor (O:0/0) are placed in series to represent
the AND condition. An OTE Valve (e.g., O:0/1) is at the end of the rung.

• Alarm with Timer Rung:

o Logic: The alarm sounds after a time delay if the Tank Empty condition is true. This prevents the alarm from
going off due to a momentary sensor flicker.

o Implementation: An XIC Tank Empty (e.g., I:0/3) and an XIO Emergency Stop (e.g., I:0/4) are in series. This
rung energizes a Timer On Delay (TON) instruction. On a separate rung, an XIC is used to check the timer's
Done bit (.DN). When the timer completes its count, the Alarm OTE is energized.

1.3 Interview Topics and Questions

This project is a great springboard for a number of ECE-related topics. Be prepared to discuss the following:

• The Problem: Clearly articulate what problem this project solves. For example, "This project automates the control
of a conveyor belt, a valve, and an alarm system based on real-world inputs, demonstrating a foundational
understanding of industrial automation."

• Component Functionality: Be ready to explain the purpose of each component, both physical and logical.

o Question: "Why did you use an XIO for the Stop button instead of an XIC?" (Answer: For safety. If the wire
to a normally closed Stop button breaks, the circuit will open, and the conveyor will stop.)

o Question: "What is the purpose of the seal-in circuit on the first rung?" (Answer: To allow the conveyor to
continue running after the momentary Start button is released.)

• Logic & Circuit Analysis: Demonstrate your understanding of fundamental logic.

o Question: "What would happen if you used OR logic instead of AND logic for the valve rung?" (Answer:
The valve would open if the sensor was on OR if the conveyor was on, which is not the desired behavior.)

• Troubleshooting: Think about how you would debug a problem with this system.

o Question: "The conveyor is not starting when you press the Start button. What are the first three things
you would check?" (Answer: Check if the Stop button is stuck, check if the emergency stop is active, and
check for a blown fuse or a disconnected wire.)
• Future Improvements: Show initiative by discussing potential upgrades.

o Question: "How would you add a counter to this system to track how many items have passed the sensor?"
(Answer: By adding a counter instruction (CTU) to the rung with the sensor input.)

• Cross-Disciplinary Questions: These questions show an understanding of how PLC systems fit into a broader
engineering context.

o Question: "What type of sensor would you use for the Tank Empty input, and would it be analog or digital?"
(Answer: A level sensor, which could be either digital (detects a specific level) or analog (measures the
continuous level). This project uses a digital input, as it's a simple ON/OFF signal.)

o Question: "How would this PLC system be integrated into a larger factory control network (SCADA)?"
(Answer: The PLC would send data to a central SCADA system via an industrial communication protocol
like EtherNet/IP.)

o Question: "What electrical considerations would you have for powering the PLC and the motors?" (Answer:
You would need to consider the voltage and current requirements, proper grounding, and using a motor
starter or variable frequency drive (VFD) to safely control the motor.)