INDUSTRIAL PRODUCTION LINE AUTOMATION

USING PLC SYSTEMs

Report submitted in partial fulfillment of the requirement for the

degree of
B.S.c (Honor)
In
Electrical and Electronic engineering
Under the supervision of
Uz. Louay farouq &
Uz. Samah Mohammed Hashim
By
Ahmed Omer Taha Ali
To
Department of Electrical and Electronics Engineering
University of Khartoum
July 2009
 Dedication

To my family for the lifelong encouragement, support and love

&

To my friend for all the good times we had together

I dedicate this work

I
 Acknowledgment
I would like to gratitude to the great god for all physical support he give
to me during the project processes.

Also I would like to thank Mr. louay Farouq and Mrs. Samah
Mohammed Hashim for their patience, support and helpful advices.

Thanks to my partner Mihdaaj Ushaari mahmoud for his faith and

encouragement.

Thanks to my family for all what they do for me among my previous

life, and I wish to reward them as soon as I can.

II
Abstract

In the late sixties of the last century the American company general electric

developed the programmable logic controllers (PLC) as an alternative to the

complex relay control system in order to use it in its car production lines. These

controllers showed very high efficiency in control systems and higher reliability in

protecting the components being controlled. In addition to this, the latter improved

characteristics made PLCs the most control system used in production Processes.

The aim of this project is to illustrate the usage of PLC in automation of production

lines and the utilization of its high capabilities to process input signals from several

sensors. This is done by implementing a small model of the filling stage of a soft

drinks production line as an application. Here several processes work in a sequential

fashion, in this stage PLCs are used to maintain this sequence.

III
 ‫ا ُمل ْس َت ْس ل َت ْس‬
‫لـ‪:‬‬

‫فٍ أواخش انسزُُبد يٍ انقشٌ انًبضٍ اسزحذثذ ششكخ جُشال األيشَكُخ انًزحكًبد انًُطقُخ انقبثهخ نهجشيجخ‬

‫انًشحالد انًؼقذ و رنك نإلسزفبدح يُهب فٍ انزحكى ثخطىط إَزبج يصبَغ انسُبساد انخبصخ‬
‫ِّ‬ ‫كجذَم نُظبو رحكى‬

‫ثبنششكخ‪ .‬أثشصد هزِ انًزحكًبد كفبءح ػبنُخ جذًا فٍ َظى انزحكى و يىثىقُخ ػبنُخ فٍ حًبَخ األَظًخ انًزحكى‬

‫ثهب‪ ،‬ثبإلضبفخ نهًُضاد األخشي انزٍ رى اسزحذاثهب ثؼذ رنك‪ ،‬انشٍء انزٌ جؼم يُهب أكثش أَظًخ انزحكى اسزخذا ًيب‬

‫فٍ ػًهُبد اإلَزبج‪.‬‬

‫َهذف هزا انًششوع إنً رىضُح اسزخذاو انًزحكًبد انًُطقُخ انقبثهخ نهجشيجخ فٍ أرًزخ خطىط اإلَزبج و‬

‫اإلسزفبدح يٍ يقذسرهب انؼبنُخ فٍ يؼبنجخ اإلشبساد انذاخهخ ػجش انحسبسبد انًخزهفخ يزؼذدح اإلسزخذايبد ‪ ،‬و‬

‫رنك ثأخز ًَىرج يصغش نًشحهخ انزؼجئخ نخط إَزبج انًششوثبد انغبصَخ كزطجُق نهزا اإلسزخذاو ‪ ،‬حُث َزى ػًم‬

‫ػذح ػًهُبد ثشكم رسهسهٍ إلَزبج انًششوة انغبصٌ ‪ ،‬فٍ هزِ انًشحهخ رزى اإلسزفبدح يٍ انًزحكًبد انًُطقُخ‬

‫انقبثهخ نهجشيجخ فٍ حفظ هزا انزسهسم نهزِ انؼًهُبد حست رضايٍ يؼٍُ‪.‬‬

‫‪IV‬‬
 Table of contents
Dedication …………………………………………………………………………………………... I
Acknowledgment…………………………………………………………………………………..... II
Abstract ……………………………………………………………………………………………... III
‫………………………………………………………………………………………………المستخلص‬ IV
Table of contents……………………………………………………………………………………. V
Chapter 1: Introduction……………………………………………………………………………. 1
1.1 Objective…………………………………………………………………………………..... 1
1.2 Introduction to industrial automation…………………………………………………….. 2
1.3 Categories of automation……………………………………………………………………. 2
1.4 Advantages and disadvantages of automation……………………………………………… 2
1.5 Automation tools……………………………………………………………………………. 3
1.6 Automated manufacturing…………………………………………………………………... 3
1.7 Thesis layout………………………………………………………………………………. 4
Chapter 2: Theoretical Background…………………………………………………………………. 5
2.1 the PLC automation technology……………………………………………………………... 5
2.2 methedology…………………………………………………………………………………. 6
2.3 how a PLC operates …………………………………………………………………………. 6
2.4 The Siemens S7-200 PLC…………………………………………………………………… 7
2.4,1 Ladder logic………………………………………………………………………… 7
2.4.2 PLC scan ……...……………………………………………………………………. 8
2.4.3 Basic requirements for PLC use………………………………………………….. 9
2.4.3.1 Programming device………………………………………………………… 10
2.4.3.2 Software……………………………………………………………………. 10
2.4.3.3 Connector cables…………………………………………………………... 10
2.4.4 STEP 7--Micro/WIN Programming Package………………………………………. 10
2.4.4.1 Using STEP 7--Micro/WIN to Create Your Programs……………………. 11
2.4.4.2 Establishing a connection…………………………………………………. 12
2.4.4.3 Downloading the Program………………………………………………… 14
2.4.4.4 Placing the S7-200 in RUN Mode or STOP mode………………………….. 15
2.5 Brushed DC electric motor………………………………………………………………... 15
2.5.1 Speed control………………………………………………………………………... 16
2.5.1.1 Using the PWM (Pulse Width Modulation) Output………………………… 18
2.5.1.2 Configuring the PWM Output……………………………………………... 18
2.6 Stepper motors……………………………………………………………………………….. 22
2.6.1 Stepper motor features………………………………………………………………. 22
2.6.2 Stepper motor types…………………………………………………………………. 23
2.6.3 Stepper motor operation…………………………………………………………….. 24
2.7 Sensors……………………………………………………………………………………….. 26
2.7.1 Proximity detectors………………………………………………………………….. 26
2.7.1.1 Inductive detection………………………………………………………….. 27
2.7.1.2 Capacitive detection………………………………………………………… 27
2.7.1.3 Sensitivity of proximity sensors…………………………………………….. 28
2.7.2 Photoelectric detectors……………………………………………………………… 29
2.7.2.1 Different detection systems…………………………………………………. 29
Chapter 3: Design And The Implementation Of The model………………………………………… 31
3.1 Sensor selection and placement……………………………………………………………... 32
3.1.1 Bottle status, conveyor 1……………………………………………………………. 32
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 3.1.2 Valve Sensor………………………………………………………………………… 33
3.1.3 Bottle status, conveyor 2……………………………………………………………. 34
3.2 The filling machine arm…………………………………………………………………….. 35
3.3 The Valve…………………………………………………………………………………… 39
3.4 Abnormal situations in the conveyor………………………………………………………... 40
3.4.1 Conveyor 1…………………………………………………………………………... 40
3.4.2 Conveyor 2…………………………………………………………………………... 40
3.5 Starting and Stopping the system……………………………………………………………. 41
3.6 Timing and sequencing of the filling machine……………………………………………. 41
3.7 PLC protection…………………………………………………………………………….. 42
3.8 The whole system…………………………………………………………………………… 43
3.9 Simulation………………………………………………………………………………….. 45
3.10 Hardware implementation…………………………………………………………………. 46
Chapter four : Results and Discussions……………………………………………………………... 47
4.1 Results……………………………………………………………………………………….. 47
4.1.1 Sequencing………………………………………………………………………….. 47
4.1.2 DC motors’ speeds………………………………………………………………….. 47
4.1.3 Stepper motor timing and delay…………………………………………………….. 47
4.1.4 Valve timing………………………………………………………………………… 48
4.2 Possible improvements……………………………………………………………………. 48
4.2.1 The stepper controller and the PTO (pulse train output)…………………………… 48
4.2.2 Weight sensors………………………………………………………………………. 49
Chapter five: project evaluation……………………………………………………………………. 50
5.1 Conclusion…………………………………………………………………………………. 50
5.2 Future work………………………………………………………………………………… 50
References…………………………………………………………………………………………… 51

Appendices
Main program code Appendix A

Stepper motor subroutine Appendix B

Wiring diagram of design Appendix C

VI
Chapter one Introduction

Chapter one

Introduction

1.1 Objective

The project’s aim is to illustrate the concept of industrial automation through a simple design of part
of a soft drink production line automated by a PLC system.

The requirements of the automated system are:

1. Start manually by external switch

2. Manipulate actions on the process according to the sensor readings as desired
3. Be able to automatically deal with abnormal situations that may occur in the process
4. Different processes in the system should be synchronized together
5. System should shutdown either manually by the external switch or automatically due to
predetermined cause

The design should include all the necessary steps taken by a control systems engineer to implement
the automated system, the steps are listed below:

1. Studying the process to be automated

2. Developing an algorithm for the system to operate with
3. Proper selection of control equipment such as sensors and controllers
4. Connecting and placing these selected items properly in the system to meet optimum system
performance
5. Developing a program code based on the suggested algorithm
6. Simulation of the automated system
7. Implementation of the system

1.2 Introduction to industrial automation

Industrial automation is the use of robotic devices to complete manufacturing tasks. In this day and
age of computers, industrial automation is becoming increasingly important in the manufacturing
process because computerized or robotic machines are capable of handling repetitive tasks quickly

1
Chapter one Introduction

and efficiently. Machines used in industrial automation are also capable of completing mundane
tasks that are not desirable to workers. In addition, the company can save money because it does not
need to pay for expensive benefits for this specialized machinery. There are both advantages and
disadvantages for a company when it comes to industrial automation.

Automation technology, if used wisely and effectively, can yield substantial opportunities for the
future. There is an opportunity to relieve humans from repetitive, hazardous, and unpleasant labor in
all forms. And there is an opportunity for future automation technologies to provide a growing
social and economic environment in which humans can enjoy a higher standard of living and a
better way of life.

1.3 Categories of automation

Automated machines can be subdivided into two large categories, open-loop and closed-loop
machines, which can then be subdivided into even smaller categories. Open-loop machines are
devices that, once started, go through a cycle and then stop. Closed loop machines complete to the
cycle described earlier then repeats it until it’s stopped.

1.4 Advantages and disadvantages of automation

Advantages commonly attributed to automation include higher production rates and increased
productivity, more efficient use of materials, better product quality, improved safety, shorter
workweeks for labor, and reduced factory lead times. Higher output and increased productivity have
been two of the biggest reasons in justifying the use of automation. Despite the claims of high
quality from good workmanship by humans, automated systems typically perform the
manufacturing process with less variability than human workers, resulting in greater control and
consistency of product quality. Also, increased process control makes more efficient use of
materials, resulting in less scrap. Another benefit of automation is the reduction in the number of
hours worked on average per week by factory workers.

2
Chapter one Introduction

A main disadvantage often associated with automation is worker displacement. In addition to

displacement from work, the worker may be displaced geographically. In order to find other work,
an individual may have to relocate, which is another source of stress.

Other disadvantages of automated equipment include the high capital to invest in automation, a
higher level of maintenance needed than with a manually operated machine, and a generally lower
degree of flexibility in terms of the possible products as compared with a manual system.

1.5 Automation tools

Different types of automation tools exist:

- ANN - Artificial neural network

- DCS - Distributed Control System
- HMI - Human Machine Interface
- SCADA - Supervisory Control and Data Acquisition
- PLC - Programmable Logic Controller
- PAC - Programmable Automation Controller
- Instrumentation
- Motion Control
- Robotics

1.6 Automated manufacturing

Automated manufacturing refers to the application of automation to produce things in the factory
way. Most of the advantages of the automation technology have its influence in the manufacture
processes.

The main advantage of the automated manufacturing are: more quality, reduce the lead times,
simplification of production, reduce handling, improve work flow and increase the moral of workers
when a good implementation of the automation is made.

3
Chapter one Introduction

1.7 Thesis layout

Throughout the next chapters the details of the project are shown. The second chapter describes the
components used in the project and how they were used. The design and implementation are
detailed in the third chapter. Then the results of the automated system are shown and discussed in
the fourth chapter. The conclusion reached and possible future works are discussed throughout the
fifth chapter.

4
Chapter two Theoretical Background

Chapter 2

Theoretical Background

2.1 The PLC in automation technology

Control engineering has evolved over time. In the past humans were the main method for controlling
a system. More recently electricity has been used for control and early electrical control was based
on relays. These relays allow power to be switched on and off without a mechanical switch. It is
common to use relays to make simple logical control decisions. The development of low cost
computer has brought the most recent revolution, the Programmable Logic Controller (PLC) (see
figure 2.1). The advent of the PLC began in the 1970s, and has become the most common choice for
manufacturing controls.
PLCs have been gaining popularity on the factory floor and will probably remain predominant
for some time to come. Most of this is because of the advantages they offer.

• Cost effective for controlling complex systems.

• Flexible and can be reapplied to control other systems quickly and easily.
• Computational abilities allow more sophisticated control.
• Trouble shooting aids make programming easier and reduce downtime.
• Reliable components make these likely to operate for years before failure.

Figure 2.1

5
Chapter two Theoretical Background

2.2 methodology

PLCs are advantageous over normal computer as they were built for harsh industrial environment
and have the facility for extensive input/output (I/O) arrangements. These connect the PLC to
sensors and actuators. PLCs read limit switches, analog process variables (such as temperature and
pressure), and the positions of complex positioning systems. Some use machine vision. On the
actuator side, PLCs operate electric motors, pneumatic or hydraulic cylinders, magnetic relays,
solenoids, or analog outputs. The input/output arrangements may be built into a simple PLC, or the
PLC may have external I/O modules attached to a computer network that plugs into the PLC.

2.3 How a PLC operates

PLCs consist of input modules or points, a Central Processing Unit (CPU), and output modules or
points. An input accepts a variety of digital or analog signals from various field devices (sensors)
and converts them into a logic signal that can be used by the CPU. The CPU makes decisions and
executes control instructions based on program instructions in memory. Output modules convert
control instructions from the CPU into a digital or analog signal that can be used to control various
field devices (actuators). A programming device is used to input the desired instructions. These
instructions determine what the PLC will do for a specific input. An operator interface device allows
processing formation to be displayed and new control parameters to be entered.(see figure 2.2)

Figure 2.3

6
Chapter two Theoretical Background

2.4 The Siemens S7-200 PLC

The S7-200 is referred to as a micro PLC because of its small size. The S7-200 has a brick design
which means that the power supply and I/O are on-board. The S7-200 can be used on smaller, stand-
alone applications such as elevators, car washes, or mixing machines. It can also be used on more
complex industrial applications such as bottling and packaging machines.

Figure 2.4

2.4.1 Ladder logic

Ladder logic (LAD) is one programming language used with PLCs. Ladder logic uses components
that resemble elements used in a line diagram format to describe hard-wired control.

Figure 2.5

7
Chapter two Theoretical Background

The left vertical line of a ladder logic diagram (figure 2.5) represents the power or energized
conductor. The output element or instruction represents the neutral or return path of the circuit. The
right vertical line, which represents the return path on a hard-wired
Control line diagram, is omitted. Ladder logic diagrams are read from left-to-right,
top-to-bottom. Rungs are sometimes referred to as networks. A network may have several control
elements, but only one output coil.
In the example program shown example I0.0, I0.1 and Q0.0 represent the first instruction
combination. If inputs I0.0 and I0.1 are energized, output relay Q0.0 energizes. The inputs could be
switches, pushbuttons, or contact closures. I0.4, I0.5, and Q1.1 represent the second instruction
combination. If either input I0.4 or I0.5 is energized, output relay Q0.1 energizes.

2.4.2 PLC scan

The S7-200 executes a series of tasks repetitively. This cyclical execution of asks is called the scan
cycle. As shown in Figure 2.6, the S7-200 performs most or all of the following tasks during a scan
cycle:
- Reading the inputs:
The S7-200 copies the state of the physical inputs to the process-image input register.
- Executing the control logic in the program:
The S7-200 executes the instructions of the program and stores the values in the various
memory areas.
- Processing any communications requests:
The S7-200 performs any tasks required for communications.
- Executing the CPU self-test diagnostics:
The S7-200 ensures that the firmware, the program memory, and any expansion
modules are working properly.
- Writing to the outputs:
The values are stored in the process-image output register are written to the physical outputs.

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Chapter two Theoretical Background

Figure 2.6

2.4.3 Basic requirements for PLC use

In order to create or change a program, the following items are needed:
• PLC
• Programming Device
• Programming Software
• Connector Cable
See figure 2.7

Figure 2.7

9
Chapter two Theoretical Background

2.4.3.1 Programming device

A personal computer (PC), with STEP 7 Micro/WIN installed, can be used as a programming device
with the S7-200.

2.4.3.2 Software
A software program is required in order to tell the PLC what instructions it must follow.
Programming software is typically PLC specific. A software package for one PLC, or one family of
PLCs, such as the S7 family, would not be useful on other PLCs. The S7-200 uses a Windows based
software program called STEP 7-Micro/WIN32. The PG 720 and PG 740 have STEP 7 software
pre-installed. Micro/WIN32 is installed on a personal computer in a similar manner to any other
computer software.

2.4.3.3 Connector cables

A special cable, referred to as a PC/PPI cable, is needed when a personal computer is used as a
programming device. This cable allows the serial interface of the PLC to communicate with the
USB interface of a personal computer. DIP switches on the PC/PPI cable are used to select an
appropriate speed (baud rate) at which information is passed between the PLC and the computer.

The DIP switches of the RS-232/PPI multi master cable are set as shown on figure 2.8.

Figure 2.8

2.4.4 STEP 7--Micro/WIN Programming Package

The STEP 7--Micro/WIN programming package provides a user-friendly environment to develop,

edit, and monitor the logic needed to control your application. STEP 7--Micro/WIN provides three

10
Chapter two Theoretical Background

program editors for convenience and efficiency in developing the control program for your
application.

Computer Requirements
STEP 7--Micro/WIN runs on either a personal computer or a Siemens programming device, such as
a PG 760. The computer or should meet the following minimum requirements:
- Operating system: Windows 2000, Windows XP (Professional or Home)
- At least 100M bytes of free hard disk space
- Mouse (recommended)

2.4.4.1 Using STEP 7--Micro/WIN to Create Your Programs

To open STEP 7--Micro/WIN, double-click on the STEP 7--Micro/WIN icon, or select the Start >
SIMATIC > STEP 7 MicroWIN 32 V4.0 menu command. As shown in Figure 2.9, the STEP 7--
Micro/WIN project window provides a convenient working space for creating your control program.
The toolbars provide buttons for shortcuts to frequently used menu commands. You can view or
hide any of the toolbars.
The navigation bar presents groups of icons for accessing different programming features of STEP
7--Micro/WIN.
The instruction tree displays all of the project objects and the instructions for creating your control
program. You can drag and drop individual instructions from the tree into your program, or you can
double-click an instruction to insert it at the current location of the cursor in the program editor. The
program editor contains the program logic and a local variable table where you can assign symbolic
names for temporary local variables. Subroutines and interrupt routines appear as tabs at the bottom
of the program editor window. Click on the tabs to move between the subroutines, interrupts, and
the main program.

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Chapter two Theoretical Background

Figure 2.9

2.4.4.2 Establishing a connection

Click on the STEP 7--Micro/WIN icon to open a new project. Notice the navigation bar one can use
the icons on the navigation bar to open elements of the STEP 7--Micro/WIN project. Click on the
Communications icon (see figure 2.10) in the navigation bar to display the Communications dialog
box. You use this dialog box to set up the communications for STEP 7--Micro/WIN.

12
Chapter two Theoretical Background

Figure 2.10

This project uses the default settings for STEP 7--Micro/WIN and the RS-232/PPI Multi-Master
cable. To verify these settings:
1. Verify that the address of the PC/PPI cable in the Communications dialog box is set to 0.
2. Verify that the interface for the network parameter is set for PC/PPI cable(COM1).
3. Verify that the transmission rate is set to 9.6 kbps.

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Chapter two Theoretical Background

Figure 2.11

Double-click the refresh icon in the Communications dialog box. STEP 7--Micro/WIN searches for
the S7-200 station and displays a CPU icon for the connected S7-200 station. Then select the S7-200
and click OK.

2.4.4.3 Downloading the Program

Click the Download icon on the toolbar or select the File > Download menu command to download
the program. (See Figure 2.12) then click OK to download the elements of the program to the S7-
200.

Figure 2.12
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Chapter two Theoretical Background

2.4.4.4 Placing the S7-200 in RUN Mode or STOP mode

For STEP 7--Micro/WIN to place the S7-200 CPU in RUN mode, the mode switch of the S7-200
must be set to RUN. When you place the S7-200 in RUN mode, the S7-200 executes the program:
1. Click the RUN/STOP icon on the toolbar.
2. Click OK to change the operating mode of the S7-200.

The S7-200 can also be put in RUN or STOP mode directly from the PLC itself.

Figure 2.13

2.5 Brushed DC electric motor

Brushed DC motors are widely used in applications ranging from toys to push-button adjustable car
seats. Brushed DC (BDC) motors are inexpensive, easy to drive, and are readily available in all sizes
and shapes.

-PRINCIPLES OF OPERATION
The construction of a simple BDC motor is shown in Figure 2.14. All BDC motors are made of the
same basic components: a stator, rotor, brushes and a commutator. The following paragraphs will

15
Chapter two Theoretical Background

explain each component in greater detail.

Figure 2.14

Stator
The stator generates a stationary magnetic field that surrounds the rotor. This field is generated by
either permanent magnets or electromagnetic windings. The different types of BDC motors are
distinguished by the construction of the stator or the way the electromagnetic windings are
connected to the power source.

Rotor
The rotor, also called the armature, is made up of one or more windings. When these windings are
energized they produce a magnetic field. The magnetic poles of this rotor field will be attracted to
the opposite poles generated by the stator, causing the rotor to turn. As the motor turns, the windings
are constantly being energized in a different sequence so that the magnetic poles generated by the
rotor do not overrun the poles generated in the stator. This switching of the field in the rotor
windings is called commutation.

2.5.1 Speed control

Generally, the rotational speed of a DC motor is proportional to the voltage applied to it, and the
torque is proportional to the current. Speed control can be achieved by variable battery tappings,
variable supply voltage, resistors or electronic controls. The direction of a wound field DC motor

16
Chapter two Theoretical Background

can be changed by reversing either the field or armature connections but not both. This is commonly
done with a special set of contactors (direction contactors).

The effective voltage can be varied by inserting a series resistor or by an electronically controlled
switching device made of thyristors, transistors, or, formerly, mercury arc rectifiers. In a circuit
known as a chopper, the average voltage applied to the motor is varied by switching the supply
voltage very rapidly. As the "on" to "off" ratio is varied to alter the average applied voltage, the
speed of the motor varies. The percentage "on" time multiplied by the supply voltage gives the
average voltage applied to the motor. Therefore, with a 100 V supply and a 25% "on" time, the
average voltage at the motor will be 25 V. During the "off" time, the armature's inductance causes
the current to continue through a diode called a "flyback diode", in parallel with the motor. At this
point in the cycle, the supply current will be zero, and therefore the average motor current will
always be higher than the supply current unless the percentage "on" time is 100%. At 100% "on"
time, the supply and motor current are equal. The rapid switching wastes less energy than series
resistors. This method is also called pulse-width modulation (PWM) and is often controlled by a
microprocessor. An output filter is sometimes installed to smooth the average voltage applied to the
motor and reduce motor noise.

The S7-200 provides three methods of open loop motion control:

- Pulse Width Modulation (PWM) -- built into the S7-200 for speed, position or duty cycle
control
- Pulse Train Output (PTO) -- built into the S7-200 for speed and position control
- EM 253 Position Module -- an add on module for speed and position control

The S7-200 provides two digital outputs (Q0.0 and Q0.1) that can be configured using the Position
Control Wizard for use as either PWM or a PTO outputs. The Position Control Wizard can also be
used to configure the EM 253 Position Module.
When an output is configured for PWM operation, the cycle time of the output is fixed and the pulse
width or duty cycle of the pulse is controlled by your program. The variations in pulse width can be
used to control the speed or position in your application.
When an output is configured for PTO operation, a 50% duty cycle pulse train is generated for open
loop control of the speed and position for either stepper motors or servo motors. The built in PTO

17
Chapter two Theoretical Background

function only provides the pulse train output. Direction and limit controls must be supplied by your
application program using I/O built into the PLC or provided by expansion modules.
The EM 253 Position Module provides a single pulse train output with integrated direction control,
disable and clear outputs. It also includes dedicated inputs which allow the module to be configured
for several modes of operation including automatic reference point seek. The module provides a
unified solution for open loop control of the speed and position for either stepper motors or servo
motors.
To simplify the use of position control in your application, STEP 7--Micro/WIN provides a Position
Control wizard that allows you to completely configure the PWM, PTO or Position module in
minutes. The wizard generates position instructions that you can use to provide dynamic control of
speed and position in your application. For the Position module STEP 7--Micro/WIN also provides a
control panel that allows you to control, monitor and test your motion operations.

2.5.1.1 Using the PWM (Pulse Width Modulation) Output

PWM provides a fixed cycle time output with a variable duty cycle. The PWM output runs
continuously after being started at the specified frequency (cycle time). The pulse width is varied as
required to affect the desired control. Duty cycle can be expressed as a percentage of the cycle time
or as a time value corresponding to pulse width. The pulse width can vary from 0% (no pulse,
always off) to 100% (no pulse, always on). See Figure 9-1.

Since the PWM output can be varied from 0% to 100%, it provides a digital output that in many
ways is analogous to an analog output. For example the PWM output can be used to control the
speed of a motor from stop to full speed or it can be used to control position of a valve from closed
to full open.

Figure 2.15

2.5.1.2 Configuring the PWM Output

To configure one of the built-in outputs for PWM control, use the STEP 7--Micro/WIN Position
Control wizard. To start the Position Control wizard, either click the Tools icon in the navigation bar
18
Chapter two Theoretical Background

and then double-click the Position Control Wizard icon, or select the Tools> Position Control
Wizard menu command. (See Figure 2.16)

Figure 2.16

- -a window then pops up with two options to choose from, the first option is chosen for PWM
or PTO operation. (figure 2.17)

Figure 2.17

- Then another window opens which asks to which output is the motor going to be connected.
The S7-200 PLC gives two outputs for such operation (Q0.0 and Q0.1) (see figure 2.18)

19
Chapter two Theoretical Background

Figure 2.18

-after specifying the output a new window opens which decides whether the chosen output operates
on PWM or PTO. (See figure 2.19)

Figure 2.19

20
Chapter two Theoretical Background

-the PWM subroutine block then appears in the instruction menu and was dragged into the program
block as shown on figure 2.20.

Figure 2.20

The PWM subroutine must be excited in order to start operation, this is done by the external start
switch which is connected to I0.0 as show on figure 2.20.

The Cycle input is a word value that defines the cycle time for the PWM output. The allowed range
is from 2 to 65535 units of the time base (microseconds or milliseconds) that was specified within
the wizard.
The Duty Cycle input is a word value that defines the pulse width for the PWM output. The allowed
range of values is from 0.0 to 65535 units of the time base (microseconds or milliseconds) that was
specified within the wizard. The Error is a byte value returned by the PWMx_RUN instruction that
indicates the result of execution.

21
Chapter two Theoretical Background

2.6 Stepper motors

Stepper motors are type of DC motors that are commonly used. Stepper motors provide considerable
advantage over typical DC motors as they may be used for precise positioning in a wide range of
applications including robotics, automation, printers, copy machines rollers and disk drivers.

Stepper motors provide open-loop, relative position control. Open loop means that, when you
command the motor to take 42 steps, it provides no direct means of determining that it actually did
so. The control is relative, meaning that there is no way to determine the shaft position directly. You
can only command the motor to rotate a certain amount clockwise or counter-clockwise from its
current position. These "commands" consist of energizing the various motor coils in a particular
sequence of patterns. Each pattern causes the motor to move one step. Smooth motion may be
obtained from presenting the patterns in the proper order.

2.6.1 Stepper motor features:

Stepper motors provides a number of valuable features such as:

 Excellent rotational accuracy.

 Large torque.
 Small size.
 Work well over a wide range of speeds.
 Can be used for motion or position control.

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Chapter two Theoretical Background

2.6.2 Stepper motor types:

Stepper motors are available in two types:

1) Bipolar motors, with two coils. These have four wires on them. They are tricky to
control because they require changing the direction of the current flow through the
coils in the proper sequence.

2) Unipolar motors (used in project). These have six or eight (or sometimes five) wires,
and can be controlled from a microprocessor. A Unipolar stepper motor has four
fixed coils arranged around a magnetized rotor, as shown on figure. Typically, the
coils are arranged in two centre tapped pairs, on opposing sides of the motor. Driving
current through any coil will cause the rotor magnet to be attracted to it, and by
sequencing the drive current though each coil in turn, the motor can be made to rotate
continuously. Higher torque can be achieved if two coils are energized at a time, and
by alternating between one and two coil drive states, half stepping mode can be
realized.

Stepper motors vary in the amount of rotation delivered per step. They can turn as
little as 0.72 degree to as much as 90 degrees per step. The most common motors are
in the 7.5 degrees- to 18 degrees-per-step range. Many have integral reduction gear
trains so that they have even higher angular resolution. Because the motors are open-
loop, if you do manage to mechanically overwhelm the motor and turn the shaft to a
new position, the motor will not try to restore itself to the old position.

23
Chapter two Theoretical Background

Figure 2.21 unipolar stepper motor coils configuration

2.6.3 Stepper motor operation

To illustrate this, let’s consider the unipolar motor( shown in figure 2.22 below). Say that it is
required to rotate the permanent magnet rotor four steps in a clockwise direction.

Figure 2.22 unipolar motor operation

At first look, it seems that the simplest way to do this is by energizing coil a so that the permanent
magnet rotor is attracted to it. Then energizing coil b and cutting the current from coil a. the
energizing coil c and cutting the current from coil b and so on. By this sequence the rotor will rotate
in a clockwise direction, to reverse the rotation just apply voltage to coils in a reverse sequence.
The method mentioned above is simple but doesn’t afford the maximum possible torque. Maximum
torque is achieved by energizing two coils at a time so that the rotor is always between the two coils.
Energizing sequences are given in table.1 and table.2 below.

24
Chapter two Theoretical Background

Step Coil a Coil b Coil b Coil c

1 1 0 0 0

2 0 1 0 0

3 0 0 1 0

4 0 0 0 1

Table.1 Full stepping half torque sequence

Step Coil a Coil b Coil b Coil c

1 1 1 0 0

2 0 1 1 0

3 0 0 1 1

4 1 0 0 1

Table.2 Full stepping double torque sequence

Both methods are called full-stepping approach because the rotor steps from coil to coil or the
midpoint of two coils to the other midpoint. This is in contrast to half-stepping where it possible to
move the rotor from one coil to the midpoint next to that coil. This operation mode is demonstrated
in table.3. The major drawback of this mode is that the torque is not constant; when the rotor steps to
the midpoint between two coils it experienced double the torque when it is attracted by a single coil.
In the first case the current running through two coils provides the necessary power for the rotor
holding torque.

25
Chapter two Theoretical Background

Step Coil a Coil b Coil b Coil c

1 1 0 0 0

2 1 1 0 0

3 0 1 0 0

4 0 1 1 0

5 0 0 1 0

6 0 0 1 1

7 0 0 0 1

9 1 0 0 1

Table.3 half stepping sequence

2.7 Sensors

2.7.1 Proximity detector

Proximity detectors operate by remote control without physical contact with the object detected.
They are thus a common feature of automated systems in all sectors of industry (mechanical,
foodstuff and chemistry). There are two main types of proximity sensors, inductive and capacitive.
Figure 2.23 show a proximity sensor

26
Chapter two Theoretical Background

Figure 2.23

2.7.1.1 Inductive detection

The main component of an inductive detector is an oscillator whose windings form the sensitive
surface. An ac magnetic field is created at the front of this surface. When a metal screen is placed in
this field, induced currents form an additional load which causes oscillations to stop.

Figure 2.24

2.7.1.2 Capacitive detection

The main component of a capacitive detector is an oscillator whose capacitors form the sensitive
surface. When a conductive or insulating material with a permittivity > 1 is placed in this field, it
modifies the coupling capacitances and causes oscillations.

27
Chapter two Theoretical Background

Figure 2.25

Advantages of this type of device

- No wear, possibility of detecting fragile, freshly painted objects, etc...
-Ideal for electronic automation systems
-Consideration of short duration information.
-Excellent withstand to industrial environments
-Lifetime not affected by the number of operating cycles.
2.7.1.3 Sensitivity of proximity detectors
The sensitivity of both sensors may be adjusted in order to read objects within a specified range. -
This adjustment is done by changing the potentiometers’ value as shown in figure

Figure 2.26

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Chapter two Theoretical Background

2.7.2 Photoelectric detectors

These are the best known detectors: their possibilities (large range, detection without contact and of
all kinds, diversity of mounting and accessibility thanks to fiber optics, etc....) make them the most
popular sensors at present in a wide variety of areas.
Composition
- These detectors are made up of a light emitter, often of a light emitting diode (LED) which is
able to emit radiation invisible to the human eye. Moreover its modulated emission
guarantees a high degree of immunity to stray light as well as a virtually unlimited lifetime.

Figure 2.27

- These detectors are made up of a light emitter, often of a light emitting diode (LED) which is
able to emit radiation invisible to the human eye. Moreover its modulated emission
guarantees a high degree of immunity to stray light as well as a virtually unlimited lifetime.

They are also fitted with a light receiver, in many cases a phototransistor which is a transistor
switching due to the presence of light.
The light emitter and receiver can be housed in the same box or in two separate boxes according to
which detection technique is used.
-Shaping and amplification of the informational image is the task of electronic components either
built into or separate from the sensor (Schmitt trigger and operational amplifiers). The object is
detected when it causes the intensity of the light beam to vary on the receiver or when it interrupts
this beam.

2.7.2.1 Different detection systems

Photoelectric sensors detect objects in two manners
1. Detection by sending back the light emitted
2. Detection by blocking the light emitted

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Chapter two Theoretical Background

In this type three systems are available

- Barrier (used in project)
- Reflex
- Polarized reflex

The barrier system consists of a transmitter device and a receiver device mounted facing
each other. When an object passes between the two devices it blocks the light from reaching
the receiver which in turn gives a signal.

Figure 2.28

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Chapter three Design And The Implementation Of The model

Chapter three

Design And The Implementation Of The model

Several industrial plants were visited which included Coca Cola, Vita and Sigmatau. They helped in
understanding the nature of the automated processes and its implementation issues. These issues
start from the proper selection of required automation equipment such as sensors and controllers to
the required sequencing and timing of the inter-process operations and how to combine all of these
aspects into one coherent system.

The coca-cola and vita visits helped in studying the soft drink production line. At first it was
intended to design a PLC automation system for such a production or part of it. But due to the
limited financial resources as well as the inability of verifying the design, it was decided to build a
small simple model of part of the production line then apply an automation system to it.

This model represents the filling stage of the production line. In this stage the following operations
occur:-

1. the empty bottles enters the filling machine from a conveyor which is moving at a
constant speed,
2. after entering the filling machine the bottle rests in one of four arms (at right angles to
each other) mounted on a stepper motor which moves the empty bottle precisely to where
the valve is and stops,
3. the valve then opens for a predetermined time quantum and closes,
4. then the arm moves the bottle to the other end of the filling machine where it exits via the
second conveyor,
5. sometimes an abnormal situation occurs were a bottle may fall while on the conveyor so
it is to be removed using a solenoid arm,

The intended design is as follows. First conveyor 1 starts moving as it is influenced by dc motor
which it’s speed is controlled moving the empty bottles towards the filling machine at constant rate
and equally spaced at a predetermined distance to avoid jamming at the filling machine as well as

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Chapter three Design And The Implementation Of The model

maintaining process synchronization, this will be described later. Then as an empty bottle
approaches the filling machine it’s position should be sensed as whether it’s standing up or lying
down, if it’s standing up it should be let into the filling machine otherwise it’s removed by the
solenoid arm. If the bottle was let in then the stepper controlled arm should move this bottle
towards the valve location at some predetermined speed to meet process synchronization. The bottle
position is then sensed to verify it had reached the valve then the valve opens for a predetermined
amount of time and closes. Meanwhile when the first bottle is under the valve a second bottle enters
the filling machine and rests at the next arm. Then this arm moves the second bottle toward the
valve and since these arms move together the first bottle moves towards its exit point (conveyor 2).
At the end of conveyor 2 the exiting bottles are counted to keep record of the number of filled
bottles. Sometimes some bottles may leave the filling machine empty or partially filled, this occurs
due to a valve fault. This issue is to be overcome by sensing the status of the bottles and either they
are removed or let through.

The process is to be started manually by the operator using a switch and then terminated either
automatically or manually. Manual termination maybe due to some fault in one or more of the
machines of the production line. Automatic termination is when the number of filled bottles reaches
some predetermined value according to the supply and demand conditions.

3.1 Sensor selection and placement

Proper selection and installment of condition sensing equipment are a critical task to enhance
optimum system performance. This section gives an insight to the how the used sensors were
designed to indicate all necessary information required by the PLC in each stage.

3.1.1 Bottle status, Conveyor 1 In

this stage the empty bottles are to be sensed to whether they are standing up or lying down. The
latter situation occurs very rarely in the conveyor due to the slow conveyor speed and relative large
weight of the bottles, in the vita factory the filling machine was placed slightly higher than the
conveyor so that lying bottles would just slide under it to some collection basket.

Two capacitive proximity sensors were chosen for this case after testing and yielding good results in
the laboratory. The tests showed that this sensor could detect glass presence within a specific
distance range.

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Chapter three Design And The Implementation Of The model

The two sensors were placed on top of each other as shown schematically on figure 3.1. The bottom
sensor detects the bottle presence and the top one indicates that if this bottle is standing up or not.

Throughout the rest of this text the bottom and top sensors will be referred to as S1 and S2
respectively for convenience. S1 and S2 are connected to the PLC inputs I0.1 and I0.2 and will
provide a high logic state to these inputs when an object is sensed. In the program code they
resembled as normally open switches. (See appendix A for program code)

Figure 3.1

3.1.2 Valve sensor

Here the empty bottle should be sensed that it has reached the valve in order to open the valve. For
this case two techniques have been introduced and tested but one of them was used.

The first technique suggested placing light reflectors on all four arms and one photoelectric reflex
sensor on the side opposite to the valve. When one arm reaches the valve location the adjacent arm
will face the sensor, as all four arms rotate together, thus resulting in a sensor reading. This
technique was easy in implementation and yielded good results in indicating the arm position but it
had one drawback, it only showed that one arm was at the valve location but not showing whether
that arm had a bottle or was the bottle already filled or not.

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Chapter three Design And The Implementation Of The model

The second technique helped overcome the first issue by using a capacitive proximity sensor instead
placed below the valve as shown on figure 3.2. The sensor showed the existence of a bottle
underneath the valve. Throughout the rest of the text this sensor will be referred to as S3. This
sensor is connected to I0.3 of the PLC and resembled in program code as normally open switch.

Figure 3.2

3.1.3 Bottle status, conveyor 2

In the third stage the objective is to sense the number of exiting full bottles. In the vita factory this
was a real problem and was done ‘literately’ manually, a worker sat next to the second conveyor
holding a specimen bottle. If any off the bottles in the conveyor mismatched the specimen’s level
the worker removes the bottle.

For this stage a polarized photoelectric transmitter/receiver sensor was placed as shown on figure
3.3. Assuming that the filled bottle contained an opaque liquid, as in most of the cases, the light will
be blocked from reaching the receiver thus indicating a filled bottle. Laboratory tests were done to
verify the theorem and yielded good results. For the rest of the text this sensor will be referred to as
S3, it’s connected to I0.4 of the PLC and resembled as a normally open switch in the program code.

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Chapter three Design And The Implementation Of The model

Figure 3.3

The removal techniques is discussed in section 3.5

3.2 The filling machine arm

As was described earlier the four arms in the filling machine are tied as one mechanism that routes
the bottles through the filling machine. Every time a bottle enters the filling machine the arm
mechanism rotates by 90 degrees moving an empty bottle to the valve and a full one to conveyor 2.
This rotation action occurs at a predetermined constant speed as to hold for the whole process
synchronization.

The operation of the stepper motor was fully described in chapter 2, next is shown how the desired
mode of operation is designed.

The stepper motor used makes a full revolution of 360 degrees in 48 steps that is 7.5 degrees per
step. Therefore 90 degrees is done by moving 12 steps. Each of these steps was excited by a pulse to
one of the stepper inputs as was described in chapter 2, the stepper inputs are to be connected to the
PLC outputs Q0.4 to Q0.7 indirectly via protection relays. The protection relays are discussed later.
The length of each pulse determined the speed and was calculated as follows.
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Chapter three Design And The Implementation Of The model

Desired speed for 90 degrees revolution (12 steps) = 4 seconds

→ Time for 1 step = 4/12 =0.25 seconds

→length of one pulse = 0.25 seconds = 250 millisecond

→frequency of the pulse switching between outputs = 1/0.25 = 4 Hz

In order to implement the above requirements using Microwin software a separate program was
written to control the stepper motor and is called from the main program as a subroutine. This
subroutine is excited or called when S1 and S2 indicate a bottle has entered the machine.

The logic of this subroutine is shown in the algorithm in figure 3.4.

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Chapter three Design And The Implementation Of The model

2 capacitive proximity
sensors

NO Bottle
entered?

YES

Call stepper
subroutine

Clear counter

Put pulse on
line 1 for 0.25
seconds

Put pulse on
line 2 for 0.25
seconds

Put pulse on
line 3 for 0.25
seconds

Put pulse on
line 4 for 0.25
seconds

Increase
counter by 1

NO YES
Counter = 3 Exit subroutine

Figure 3.4

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Chapter three Design And The Implementation Of The model

The software implementation for such logic is as follows.

1. First a subroutine block must be inserted into the main program, this block is dragged from
the instruction menu under call subroutines. See figure 3.5.

Figure 3.5

From the figure it’s shown that this subroutine is initiated by I0.1 and I0.2 which are the two
capacitive proximity sensors S1 and S2 respectively.

2. Next an icon at the bottom of the page labeled SBR_0 navigates to a new window to write
the subroutines code. See figure 3.6.

Figure 3.6

Note the icon on the right PWM0_RUN, this is the subroutine for the PWM operation discussed
earlier but is locked and the user may not modify it unlike a normal subroutine.

To construct the loop the simple FOR instruction was used to repeat the loop three times. The ‘FOR’
instruction was dragged from the instruction menu from under Program control. See figure 3.7

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Chapter three Design And The Implementation Of The model

Figure 3.7

The INIT field shows the starting count number and FINAL shows the final count number. The
INDX field species a memory address to store current count value in.

Next timers were used to control the output pulse length. Each timer introduced a delay of 0.25
seconds before switching the pulses between the 4 lines.

For program code see appendix A and appendix B.

3.3 The valve

The valve was programmed to open for 2 seconds when the S3 reads a bottle and then closes. The 2
seconds seems as a small amount of time to fill a bottle but because the liquid is pumped at very
high pressure 2 seconds is fairly enough. This is not just a clueless assumption but a fact observed
during the field visits.

The control of the valve was very simple compared to the control of the dc motor and dc stepper
motor. The input from the sensor enables a timer which in turn activates the output to the valve for 2
seconds. For program code see appendix A

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Chapter three Design And The Implementation Of The model

3.4 Abnormal situations in the conveyor.

As was described earlier two abnormal situations may occur in the conveyors. Next is described
how these behaviors are dealt with.

3.4.1 Conveyor 1
In this conveyor the problem faced was a bottle lying down. It was shown earlier how this situation
is sensed by the two sensors. When these two sensors indicate a falling glass a solenoid arm, which
moves across the conveyor, removes the bottle. The solenoid arm is connected to the output Q0.3 of
the PLC which is activated only when I0.1 reads ON (bottom sensor) and I0.2 reads OFF (top
sensor). The placement of the arm is shown below in figure 3.8.

Figure 3.8

3.4.2 Conveyor 2
The situation of a lying down bottle would not occur in the second conveyor as it was designed to
operate at lower speed compared to conveyor 1 for reasons described later. The problem faced here
is an empty bottle or partially filled bottle, this may occur due a valve fault which occurs very
rarely. This situation is solved by introducing an electromagnet controlled gate placed on the
conveyor as shown on figure 3.9.

The gate is connected to Q0.3 output from the PLC. When the sensor reads a full bottle it activates
the output Q0.3 in order to open the gate for that bottle to pass, otherwise the bottle is discarded
from the conveyor.

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Chapter three Design And The Implementation Of The model

Figure 3.9

3.5 Starting and stopping the system

To start the system a switch was designed to be manually closed (put on ON state). This switch is
connected to I0.0 of the PLC and promotes the activation of the outputs Q0.0 and Q0.1 which are
connected to the DC motors moving the conveyors as was shown earlier.

To stop the system manually the same switch is opened and the whole system then terminates, this
action is done by using the STOP instruction which is activated by opening the manual switch. The
STOP instruction causes a transition in the PLC from RUN mode to STOP mode thereby
terminating the whole process.

For the system to stop automatically a counter is assigned to count the number of full bottles exiting
through conveyor 2, when this counter reaches a predetermined value it activates the STOP output.
The counter was set to activate STOP when 100 bottles were counted, the counter itself was
incremented with each reading of the photoelectric sensor. In the program the counter is first reset
by I0.0 (manual switch) and incremented by I0.4 (photoelectric sensor)

3.6 Timing and sequencing of the filling machine

It was earlier calculated that the 90 degree revolution of the arm mechanism took 4 seconds, and the
arm then stayed still for 2 other seconds under the valve. That is a total of 6 seconds, this means that
the next bottle should about 4-6 seconds apart from the first one. That is the second bottle should

41
Chapter three Design And The Implementation Of The model

enter the filling machine and rest in the available arm while the first bottle is being filled. A
difference of 5 seconds was designed to be the time interval at which successive bottles entered the
filling machine. How this time interval was attained was the tricky part and is described below.

First a distance between two successive bottles should be defined, this distance should be just big
enough so that a falling bottle may not interrupt other bottles. An adequate distance of 0.25 meters
was decided. Therefore to obtain a time interval of 5 seconds the speed of conveyor 1 should be 0.25
meters per 5 seconds, that is 0.05 meters per second.

Another aspect in the timing design was that of the initialization of the stepper motor. As it was
shown the rotation action is excited by the reading of the two sensors, S1 and S2. This causes the
rotation to start before the bottle rests in an arm because the sensors are placed before the filling
machine at a distance of 0.125 m. This spacing was designed to give adequate space for the arm to
move freely and not disturb the sensor readings.

This problem was solved by introducing a time delay before starting the rotation. Since the conveyor
is moving at 0.05 meters per second the bottle will rest at the arm after 2.5 seconds from passing the
sensors (time = distance / speed). Therefore the time delay was chosen to be 3.5 seconds (2.5
seconds + 1 second for the valve to close) and was programmed using a timer that is excited by the 2
sensors which in turn calls the stepper subroutine after 3.5 seconds.

3.7 PLC protection

Although PLCs are designed to stand the harsh conditions of the industrial plants they must still be
protected from electrical damage especially from inductive loads such as motors.

Inductive loads may damage the PLC because of their feedback current, thus they are supplied by
an external source (see figure 3.10). This external source is connected to the motors with relays and
these relays are energized by the PLC outputs.

Next the PLC outputs’ current was also provided by an external source. This was done although the
PLC had an internal current source (see figure 3.10) so as not to draw much current from the PLC
thereby causing over heating of the PLC.

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Chapter three Design And The Implementation Of The model

Figure 3.10

3.8 The whole system

Throughout the previous sections in this chapter every part of the process was explained. Although
some hints may have been shown earlier to how some parts are related to others, in this section it is
shown how all these parts are grouped together to form the whole process. The algorithm on figure
3.11 shows the whole process.

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Chapter three Design And The Implementation Of The model

start

No Operation /
External switch state OFF Terminate whole
process

ON

OFF

Start conveyor 1
Clear bottle
Sensor 4 staus
counter
Start conveyor 2

OFF YES

Sensor 1 status Open gate

ON NO

Activate arm to Increment bottle

OFF Sensor 2 status
remove bottle counter

ON ON

Wait for 3.5 s then rotate

Counter = 100
arm for 90 degrees

YES

Terminate whole
No Operation OFF Sensor 3 status
process

ON

Open valve and

End
start timer

Close valve YES Timer = 2 s NO No Operation

Figure 3.11

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Chapter three Design And The Implementation Of The model

Remarks on the algorithm

-the details of each independent procedure were shown earlier like for the stepper motor, therefore
the reader should look back into the previous sections for the detailed logic. As was mentioned
above this algorithm shows the interconnection of the system.

-note that the algorithm states that the check for S3 occurs only after the 90 degrees revolution, this
was intended to remove the ambiguity of whether the bottle under the valve was the filled bottle or a
new one. In the program code this issue was solved by merging the valve operation within the
stepper motor’s subroutine.

-also the status of sensor 2 is checked only if S1 reads an object unlike sensor 1 and sensor 4 which
are checked continuously.

For whole program code see appendix A

For the connections of the system see appendix C

3.9 Simulation
Unexpectedly the simulation of the design turned out to be one of the most tedious stages of the
project due to the following reason. The Siemens Company never supplied a software simulator with
its product, so a free license simulator that was found in the laboratory was used. This simulator did
not have many essential instructions built in it such as the ‘subroutine’ and ‘loop’ instructions which
were used extensively in the program as was shown earlier throughout this chapter. In this section it
is shown how the project was simulated although of the previously mentioned facts.

The available simulator was used as follows,

1. The outputs to the two DC motors were changed from PWM operation to normal
operation as simple contactors. Also the four outputs to the stepper motor were
substituted for one output which was Q0.5 to operate as a normal contactor, and the input
from sensor 3 was removed. These two actions were done to verify that the logic
sequence will call any of the subroutines as desired by the design.
2. Then the configuration of the simulator was matched to design, this was done by
changing CPU TYPE to S7 200 224XP and CPU no. to 1
3. Then the program code was loaded into the simulator

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Chapter three Design And The Implementation Of The model

4. The simulator was then put on run mode

5. Finally by manipulating input values the outputs were observed for all possible input
patterns by observing the sequencing of operations as well as their timing.

3.10 Hardware implementation

The hardware implementation was the disappointing stage during the lifetime of the project as it was
not funded. First, the PLC, its connecting cable, and all four sensors were available in the laboratory.
Then individual efforts helped in acquiring the 2 DC motors and the stepper motor. Then due to the
limited resources, the parts of the process (conveyor, valve, solenoid arm etc) were not acquired.
The valve, solenoid arm and electromagnetic gate were modeled as LEDs connected to the PLC
outputs shown earlier. The conveyor was not built thus the required output speed of the DC motor to
attain a conveyor speed of 0.05 meters per second could not be calculated as discussed earlier.
Therefore only a flag was connected to the motors’ shafts to observe there speed.

All necessary relays and power sources were available in the laboratory and were connected as it
was suggested in the design. A 24 volts DC source was used to drive the PLC outputs as well as the
stepper motor which operated under 24 volts, and a 9 volts DC source was used to drive the two DC
motors.

Finally the physical model was built by substituting the unavailable parts as was shown and put into
action.

For connections see appendix C

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Chapter four Results and Discussions

Chapter four

Results and Discussions

4.1 Results

After the connection of the physical system that was shown in the previous chapter, the system was put into
action and yielded relatively good results but still had some flaws. These results and flaws are discussed
throughout this chapter.

4.1.1 Sequencing

First the sequencing of the operations was perfect. The outputs from the PLC were excited as desired
according to different input patterns, these input patterns were all taken into consideration in chapter 3.

- The two DC motors started and stopped when the start switch was ‘ON’ and ‘OFF’ respectively.
- The stepper motor took its 90 degrees revolution when S1 and S2 where on.
- The LED connected to Q0.2 (arm) lighted when only S1 was ‘ON’
- The LED connected to Q0.3 (valve) lighted when S3 was ‘ON’
- The LED connected to Q1.0 (was) lighted when S4 was ‘ON’
- The system shutdown automatically after 100 readings for S4. This part was tedious in testing as S4
was put on ‘ON’ state then ‘OFF’ state exactly 100 times to test the system.

These results verified that the logic of the program code drives the application in the desired sequence of
events.

4.1.2 DC motors’ speeds

Second the speeds of the two motors were observed. This test was done by putting identical flags in both
motors and counting how many revolutions each flag took in 10 seconds. The result showed that DC motor 1
was faster than DC motor 2 as desired, but these speeds were not measured.

4.1.3 Stepper motor timing and delay

Then the speed of the stepper motor was tested. The results showed that the time for a 90 degree revolution
was slightly larger than that desired. The error was not constant throughout the tests and was in the range of
1 - 4 seconds approximately, the term ‘approximately’ was introduced because the timing measurement was
done by a stop watch thus not accurate but it was obvious that there was an error which was not constant.

47
Chapter four Results and Discussions

This timing error was not due to program fault but due to the mechanical nature of the physical PLC outputs.
After deeper investigation in the PLC structure it was found that the outputs of the PLC were relays which are
energized by internal small signals from the microprocessor of the PLC. These relays could not adapt to the
high switching frequency of the pulses suggested by the design which was 0.25 seconds. A test was made to
verify this point, the pulse times were slightly increased (decreasing motor speed) by changing the program
code and it was observed that the error has been reduced but not eliminated. The pulse time could only be
slightly increased as to keep the stepper motor from heating up thus being damaged. This fact was retrieved
from the stepper motor’s manual itself which suggested that the motor should be operated within a specific
range of speeds, slower speeds may damage the motor as more current is applied to it.

Unfortunately before a solution could be figured for this issue the stepper motor was damaged due to short
circuit that resulted from improper wiring. How this issue may be solved is discussed in the next section.
Note that this would have not been an issue in the outputs Q0.0 and Q0.1 as they were specially designed
with high-speed switching capabilities.

Also a delay of 2.5 second occurred before the stepper started operation as desired,

4.1.4 Valve timing

The LED on Q0.3 (valve) showed good results in its timing, it started after S3 was ‘ON’ and closed after
exactly 2 seconds.

4.2 Possible improvements

In this section it’s shown what improvements could be added to the design and how these improvements
upgrade the performance of the system.

4.2.1 The stepper controller and the PTO (pulse train output)

A stepper controller is a device that receives a specific number of pulses from an external source through one
line, then this controller moves the stepper motor by a number of steps equal to the number of the pulses. It
does this by distributing the pulses among the four motor lines in increasing order. To clarify this point
suppose that the input was 6 pulses, the controller then puts a pulse in each of the lines in the following
sequence, 1 2 3 4 1 2. Also the width of the input pulses is equal to the width of each output pulse. A pulse
train is simply a sequence of pulses of 50% duty cycle as shown in figure 4.1.

Figure 4.1
48
Chapter four Results and Discussions

The S7-200 as was shown earlier supports pulse train output (PTO) through Q0.0 and Q0.1. Then this output
could be used as an input to the stepper controller. This method totally eliminates the timing error described
in section as the stepper controller was specially designed for accurate positional and speed control. Another
advantage of this method is that it reduces the number of outputs from the PLC needed to drive the stepper.
The stepper controller was not used in the design because of the inability to acquire it.

4.2.2 Weight sensors

An analogue weight sensor could be used instead of the photoelectric sensor to sense the status of the exiting
bottles. This weight sensor is advantageous over the photoelectric sensor because the latter one measures only
the presence of a full bottle but cannot differentiate between a partially full bottle or no bottle, but the weight
sensor provides the ability to differentiate between a full bottle, an empty or partially filled bottle, and no
bottle. Thus if a weight sensor was used the logic of operation may be improved as follows. Instead of
opening the gate for each full bottle the photoelectric sensor reads, the gate will be normally open and closes
when a partially filled bottle is read by the weight sensor.

The reader should note that an analogue weight sensor provides an analogue signal relative to the measured
weight, such an input must be connected to the PLC indirectly through an analogue input module. Both the
analogue weight sensor and input module could not be acquired for use in the project.

49
Chapter five Project Evaluation

Chapter 5

Project Evaluation

5.1 Conclusion

After the project was fulfilled in all stages (design-simulation-implementation) several facts were
concluded. Next is shown why these conclusions were reached.

1. In order to achieve optimum automation performance operation oriented devices must be

used. This is because of the timing errors observed in the stepper motor operation, these
errors could be eliminated by using a stepper motor controller (as was discussed in chapter
four). Also a DC motor speed controller is available.
2. Different equipment may give similar results for a specific task but some of them may
provide larger system flexibility than others. This was concluded because it was learned that
a weight sensor provides a more readings than the photoelectric polarized sensor. Recall the
discussion in section 4.2.2.
3. In addition to the components used in the project, the previous two conclusions, a third
conclusion is reached. That is although industrial automation is cost-effective in the long-
term its initial costs are very high since in order to achieve optimum performance high
quality components are required.

5.2 Future work

The project considered only part of the production line, thus it is extendable. Much more future
work can be done to complete the whole production line. When introducing new stages of the
production line for example the washing machine (which comes prior to the filling stage), as well
controlling the washing machine it must be synchronized with the filling machine. In the same
manner all processes of the production line must be synchronized as well as inter-process
synchronization which was considered in this project.

After finishing the whole production line design a further step could be taken that is to develop cost
estimation for the system. The cost estimation is an important stage that the control system engineer
is entitled to after finishing the design.

50
Chapter five Project Evaluation

Also a human machine interface (HMI) may be developed in order to monitor process variables and
system performance and apply changes remotely. Although an HMI system will be very useful it is
not recommended to apply to such an application. That’s because soft drink production lines are
considered to be a simple kind of production lines compared to other industrial applications such as
the car industry and petrochemical industry. Therefore the high cost of HMI installment makes the
HMI system undesired as the system can operate just fine without it.

51
 References

References

[1] www.wikipedia.org

[2] www.howstuffworks.com

[3] Siemens SIMATIC S7 200 programmable controller manual, SIEMENS company.

[4] Ladder logic language reference, unknown author

[5] DC Motor Control Systems, Rick Bickle

[6] Computer Control #2 PM stepping motors, unknown author

[7] www.imagesco.com

[8] Detection workshop technical manual, SHNIEDER company

[9] Detection workshop exercise book, SHNIEDER company

[10] Automating manufacturing systems with PLCs, version 5.0, Hugh Jack

[11] Towards automatic verification of ladder logic programs, Bohum Zoubek, Jean-Marc Roussel,
Marta Kwiatkowska

[12] Speed control and Positioning using standard drives, Micro Automation SET 1, SIEMENS
company

51
Appendix A main program code

Appendix A – program code

A-1
Appendix A main program code

A-2
Appendix A main program code

A-3
Appendix B stepper motor subroutine

Appendix B – stepper motor subroutine

B-1
Appendix B stepper motor subroutine

B-2
Appendix B stepper motor subroutine

B-3
 Appendix C

Output from PLC

Input from PLC
Cable

gate

DC motor 1
External switch
Appendix C – Wiring diagram of design

S2 (top sensor)
S3 (valve sensor)

valve
S4 (photosensor)

Conveyor 1 Conveyor 2

DC motor 2
S1 (bottom sensor)
arm

Nuetral lines and relay connections are

not shown on diagram. Stepper
motor
Wiring diagram of the design

C-1