JOURNAL OF INFORMATION, KNOWLEDGE AND RESEARCH IN

ELECTRONICS AND COMMUNICATION ENGINEERING

ISSN: 0975 – 6779| NOV 16 TO OCT 17 | VOLUME – 04, ISSUE – 02

PLC and SCADA based color mixing process

M.H.Gholve,Anuradha S. Thorat ,Dhanshri B. Kshirsagar,Bhagyashree D. Nimbalkar
Department of electronics and telecommunication , RDTC SCSCOE, Dhangawdi, pune ,india
[email protected]
[email protected]
[email protected]
[email protected]

Abstract— In this color mixing machine we use three tanks which are of Red, Blue and Green. The three tanks consist of level
sensor and fitted with hydraulic line. The hydraulic line consist of solenoid valve .The tank consists of color of Red, Blue and green.
The water flows from the mixing tank through solenoid valve. The solenoid valve is a digital output device that is connected to the
PLC The solenoid valve connected to 3rd tanks.
The SCADA is used to monitor the system. PLC is also used for the internal storage of instruction for theimplementing
function such as logic, sequencing, timing, counting and arithmetic to control throughdigital or analog input / output modules
various types of machines processes.

Keywords— Color, Automated, Quality, Efficiency, Mixing, Process, SCADA, Monitor, PLC

Introduction wheel. Other common color wheels represent the light

model (RGB).
Over the years the demand for high quality ,greater
efficiency and automated machines has increased in
the industrial sector of different plants. The process
control of color making which is the most important
process in any color plant like Asian paints and its
automation is the precise effort of this paper .In order
to automate a color plant and minimize human
intervention, there is a need to develop a SCADA
(Supervisory Control and Data Acquisition) system
that monitors the plant and helps reduce the errors
caused by humans. While the SCADA is used to
Fig1.wheel cycle
monitor the system, PLC (Programmable Logic
Controller)is also used for the internal storage of B. Objective
instruction for the implementing function such as
Over the years the demand for high quality ,greater
logic, sequencing, timing, counting and arithmetic to
efficiency and quantity has increasing this globalized
control through digital or analog input/ output modules
world for various colors [2].The initial phase of the
various types of machines processes. Systems are used
paper focuses on passing the inputs of color mixing
to monitor and.
with various components. With the help of mixing
A. RYB color model tanks all colors coming from the process will be mixed
RYB(red yellow blue)make up the primary color in the required proportion [3]. Color will be mixed
criteria designing standard artist's color wheel. The using mixed motor .making color in industry which
secondary (violet orange green) makes up another tria. will be used for food beverage industry .Generally
Triads colors(purple–orange– green) sometimes called from three colors we are making nine colors with
(violet–orange–green)makes up another triad. Triads different proportions so it will be use different
are formed by 3equidistant colors on a particular color petrochemical companies .Thus what we require is a
system that collect raw data process it and presents it
in values which can be verified and compare with the

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 JOURNAL OF INFORMATION, KNOWLEDGE AND RESEARCH IN
ELECTRONICS AND COMMUNICATION ENGINEERING
ISSN: 0975 – 6779| NOV 16 TO OCT 17 | VOLUME – 04, ISSUE – 02
standard value subroutines of the coding process. thus it provides a real challenge with system involving.

C. Programmable logic controller:-

Finally, a PLC checks up output signals and adjust it
has needed. Changes are performed based on the input
In this, instead of achieving desired control and status that had been read during the first step and
automation through physical wiring of control devices, based on the result of the program execution in step
it is achieving through program say software. two – following execution of step three PLC returns a
Advantages beginning of the cycle and continually repeats these
Reduced Space, Energy saving, Modular Replacement, steps. Scanning time = Time for performing step 1+
Easy trouble shooting, Error diagnostics programmer, Time for performing step 2+ Time for performing step
Economical, Greater life and reliability, The 3. Allen Bradley PLC:- Programmable Logic
Compatibilities of PLC’S, Logic Control, PID control, Controller or PLC is an intelligent system of modules,
Operator control, Signaling and listing, Coordination which was introduced in the control, &
and communication. instrumentation industry for replacing relay based
logic [4]. Over a period of time, better I/O handling
capabilities and more programming elements have
been added along with improvement in
communication.

PLC Working
At the beginning of each cycle the CPU brings in all
the field input signals from the input signals from the
Fig. 2 working flow module and store into internal memory as process of
input signal. This internal memory of CPU is called as
process input image (PII).User program (Application)
How PLC works will be available in CPU program memory. Once PII is
Basics of a PLC function are continual scanning of a read, CPU pointer moves in ladder program from left
program. The scanning process involves three basic to right and from top to bottom. CPU takes status of
steps. input from PII and processes all the rungs in the user
Step 1: Testing input status program. The result of user program scan is stored in
First the PLC checks each of its input with intention to the internal memory of CPU. This internal memory is
see which one has status on or off. In other words it called process output image or PIQ. At the end of the
checks whether a switch or a sensor etc., is activated program run i.e., at the end of scanning cycle, the CPU
or not. The information that the processor thus obtains transfers the signal states in the process image output
through this step is stored in memory in order to be to the output module and further to the I/O driver
used in the following steps. (SCADA) picks up PII and PIQ and transfers the
image to database and this image is called driver
Step 2: Programming execution image. This driver image available in SCADA
Here a PLC executes a program instruction by database is used for graphical view of process
instruction based on the program and based on the monitoring from
status of the input has obtained in the preceding step, operator station (OS) in the central control room.
and appropriate action is taken. The action might be
activation of certain outputs and the results can be put A. Features of Allen Bradley PLC
off and stored in memory to be retrieved later in the Using Allen Bradley 1000PLC Micrologix 1000PLC
following steps. has20 digital outputs. The relationship with bit address
to input and output devices is shown in the figure
Step 3: Checking and Correction of output status

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ELECTRONICS AND COMMUNICATION ENGINEERING
ISSN: 0975 – 6779| NOV 16 TO OCT 17 | VOLUME – 04, ISSUE – 02
below .I/O Pin Configuration of AB PLC The left side three main colors. This process shown in block
of the screen shows that eh project tree while the right diagram and flow chart For the first case :selecting one
side of the screen is the programming area. Either area of the six colors on the HMI, Precise ratios of the three
can be increased in size, minimized, or closed by left main colors are required in order to form one of the
clicking the mouse on the appropriate symbol. colors to be chosen by user. The colors will be selected
in proper proportion through the ratio control process.
The mixture of colors will be mixed in the reactor tank
by mixer motor. Level will be controlled by ultrasonic
type level.

Fig. 3 Relationship of bit address to input & output

SCADA:-
SCADA stands for Supervisory Control and Data
Acquisition. As the name indicates, it is not a full
control system, but rather focuses on the supervisory
level [2].What is SCADA? It is used to monitor and
control plant or equipment. The control may be
automatic or initiated by operator commands. The data
acquisition is accomplished firstly by the RTU’s
scanning the field inputs connected to the RTU (it may
be also called a PLC– programmable logic controller.).
This is usually at a fast rate. The central host will scan Fig .4Assembly of mounting
the PTU’s (usually at as lower rate). The data is
processed to detect alarm conditions, and if an alarm is Acknowledgment
present, it will be displayed on special alarm lists.
The most important aspect of any color industry
mixing which is main part which is controlled using
8. OPERATION PLC. The method that has to be used relies on varied
The project work consists of distribution of any kind objectives like superior quality, increased efficiency,
of liquid or semi-liquid into different plants from a high profit and other such points depending upon the
main buffer storage tank. This distribution takes place purpose of the company that implies it. With the prime
automatically using the Programmable Logic objective of catering to these necessities and the needs
Controller (PLC).[5] The main reservoir and the plant, of the industrial sector, significance has been given
where the process is taking place are situated far apart here to automation This paper presented here has kept
physically .All the process of this system is in mind, the ceaseless changes that are relentlessly
automatically done, like this sensing of the raw color taking place in the contemporary scenario of the
material, opening and closing of the valve (in tank), industrial segment. Emphasis has been given to the
process taking in the plantlike heating and churning, automation process that is now rapidly taking its place
and removal of the raw color material. The successful in all plants across the globe. The Paper has furnished
operation with PLC have opened possibilities for itself to study the integral parts of the entire process
adapting automation commercially in all available involved, their implementation and the problems that
plants The implementation of the process should may show up have also been given their due
provide the user with two options: 1-User can select importance. The future work deals with the
one of the six colors which are shown on the HMI. 2- purification of water to the boiler and the air
Usercan create his own color with his own ratio of the

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Polytechnic) Dhangawadi, Tal: Bhor, Dist: Pune (Maharashtra). Page 1475
 JOURNAL OF INFORMATION, KNOWLEDGE AND RESEARCH IN
ELECTRONICS AND COMMUNICATION ENGINEERING
ISSN: 0975 – 6779| NOV 16 TO OCT 17 | VOLUME – 04, ISSUE – 02
circulation for the boiler to burn the fuel using same
automation technique. Making of product in industry
is easy with the
help of PLC.

Conclusion:
The most important aspect of any color industry
mixing which is main part which is controlled using
PLC. The method that has to be used relies on varied
objectives like superior quality, increased efficiency,
high profit and other such points depending upon the
purpose of the company that implies it. With the prime
objective of catering to these necessities and the needs
of the industrial sector, significance has been given
here to automation.
The future work deals with the purification of water to
the boiler and the air circulation for the boiler to burn
the fuel using same automation technique. Making of
product in industry is easy with the help of PLC.

References
[1] [1]Ezell, Barry, “Scenarios One and Two: Source
to No 1PS to No 1 Tank to No 2 PS to No 2 tank (High
level) for a Master-Slave SCADA System”, SCADA
Consultants, SCADA Mail List, [email protected]
(August 1997).
[2] Rockwell Automation SCADA System Selection
guide Allen-Bradley, Publication AG-2.1. 1998.
[3] Knight. U. “The Power System and its Operational
and Control Infrastructure in emergencies” from
contingency planning to crisis management.
[4] analysis of Fault-Tolerant systems, “IEEE
transactions on Computers”, vol.38, No.6, 1989.
[5] Gary Dunning, “Introduction to Programmable
Logic” Controllers, Edition third, 628 .
[6] Clarence A. Phipps, “Fundamentals of electrical
control”, Publisher The Fairmont Press, Inc.
1999,Edition2,illustrated,213,Page .162,164,165.
[7] Ramakant A. Gayakwad, “Op-Amps and Linear
Integrated Circuits”, Publisher PHI prentice hall
India, Fourth Edition, , Page no.438,439.

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