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Australian Journal of Information Technology and Communication Volume II Issue I
ISSN 2203-2843
Monitoring and Controlling of Industrial Crane using
Programmable Logic Controllers
Harpreet Singh Bedi* Krishan Arora**Rk Sharma***
[email protected]
ABSTRACT
In this paper, we will work on Programmable logic Controllers
Changed and control sequences had to be modified. PLC is a
to control the operation of an Industrial Crane and many other
small computer which is used for Automation and
Applications which is used in the industry. Earlier in Industry,
applications of Real -World Process, Such as a control of
We used certain control devices which were controlled and
Machinery on assembly lines, Timers and Counter
wired directly with the system that leads to certain irregularity
applications and other applications used the help of PLC. It
in the functioning of the whole system. To overcome the
is usually a Microprocessor. The Program which is to be
in-functionality of the system which was caused by large
written in ladder programming can use control complex
number of wires, We came cross towards Programmable logic
sequencing and is written with the help of software. The
controllers (PLC).Earlier Human controls the crane & that
Program in Plc can be stored in battery backup memory.
passes through large drawbacks such as more numbers of
Unlike other equipment’s General purpose computers, the
wires required, large faults will be there and many more
plc is well designed and manufactured for extended
difficulties in troubleshooting & repair work .Due to these
temperature ranges, immunity to noise, and is mechanically
Drawbacks the production suffers a lot and hence growth
more rugged and resistant to vibration and impact. By
decreases rapidly. This is the main reason in order to remove
implementing this project we will decreases the man power,
irregularity of relays and wiring issue we prefer PLC to
hence will increase in production of the industry [4].
control and monitor the operation of crane in the industry.
II. DEFINITION OF PLC
Keywords
–
PLC,
HMI,
automatic
control,
Hardware
configuration (crane model)
PLC is a Digital Electronic Device that uses a
Programmable memory to store instruction and to
I.
INTRODUCTION
implement function such as Timing, Counting, Logic,
Sequencing and arithmetic in order to control the machines
PLC’s were developed in the late 1960’s to eliminate the
and their processes. Input Devices such as switches,
large cost involved in changing complicated relay based
different types of sensors are used to control the input
machine control systems. These relay based systems were
switching and output devices such as motors solenoids are
very flexible; their configuration and capability and
used to control the output circuitry. Input devices e.g.
structure or complete replacement of relay based system was
switches, and output devices e.g. motors, being monitored
necessary every time when the production requirements
and controlled are connected to the PLC and then the
controller monitors the inputs and outputs according t this
program stored in the PLC by the operator and so controls
the machine or process[3].
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Australian Journal of Information Technology and Communication Volume II Issue I
ISSN 2203-2843
Basically PLC was designed as a replacement for hard wired
programmable controller, consists of two basic sections: the
delay and other timer, counters and logic Functions. PLCs
central processing unit and the input/output interface
have certain advantages that make it possible to modify a
system.
control system without having to rewrite the connections to
the input and output devices. The basic difference is that the
developer uses different set of mnemonics for different set
of instructions. Thus making it a more flexible system which
can be used to operate, monitor and control the variety of
different systems.
Figure 2:-PLC CPU Architecture
The operation of a programmable controller is relatively
simple. The input and output system is attached to the
devices that will help the plc to run and execute various
input and output functions. The input and output devices an
Figure 1:-PLC Architecture
be either analog or digital in nature which can be limit
Switches, pressure transducers, push buttons, motor starters,
I. PLC OPERATION
solenoids, etc. The input/output module makes the
connection between CPU and between input and outputs and
A PLC works by continually scanning a program. A PLC
to the concerned devices.
program is generally executed repeatedly as long as the
controlled system is running. [1]. the status of physical input
In the working Phase, CPU has to undergo three Process i.e.
points is copied to an area of memory accessible to the
it reads the data from the input devices, it executes, or
processor, sometimes called the "I/O Process table". The
performs, the control program stored in the memory system
program is designed to work from the first input to the last
And it controls and updates the output. The process of
input in a rung.
reading the input, performing and executing the functions in
Then the processor takes some time to interpret and evaluate
the memory, and updating the results and outputs is known
all the input of the rungs and then update the I/O image table
as scanning.
with the status of the outputs. This scan time may be a few
milliseconds for a small program or on a larger and speedy
The input/output system forms the interface by which field
processor and slow processor could take much longer (say,
devices are connected to the controller .The main purpose of
up to 100 ms) to run the program. If the processor takes too
the interface is to condition the various signals received
much in executing the instruction the plc response to the
from or sent to external field devices. Incoming signals from
processor will decrease. There are typically more than 3 but
sensors (e.g., push buttons, different types of switches) are
we can focus on the important parts and not worry about the
the devices which are used at input terminals. The output
others. Typically the others are checking the system and
Devices that can be started or functional like the output
updating the current internal counter and timer values [6].A
devices are connected at the output terminals of the output
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Australian Journal of Information Technology and Communication Volume II Issue I
ISSN 2203-2843
interface [2]. The system power supply provides all the
voltages required for the proper operation of the various
central processing unit sections.
Figure 3:-PLC Scanning
III. Hardware Design for the Model
Figure 4:- Experimental setup
V. PROPOSED WORK
In this paper, we first developed the ladder logic to control
the cranes in a particular direction, and then simulate the
ladder programming using Rs Logix Software for PLC.
Then design and assembled the crane model by selecting
various types of motors then checked the testing of relay
module and monitoring the voltage current and temperature
of the drives in the present scenario. Thus our proposed
work is mainly based on Rs Logix software. Let’s compare a
simple ladder diagram with its real world external physically
connected relay circuit and see the differences.
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Australian Journal of Information Technology and Communication Volume II Issue I
ISSN 2203-2843
3. They are easily programmed and have easily understood
programming language.
4. It contains programmable functions.
5. It scans memory, inputs and outputs in predetermined
manner.
6. It provides error checking diagnostics.
7. A PLC can provide some form of monitoring capabilities
8. A PLC can be effectively designed for a wide variety of
control tasks.
Figure 5:-Relay Circuit
VIIII. CONCLUSION:In the above circuit, the coil will be energized when there is
a closed loop between the + and - terminals of the battery.
The same circuit can be made with the help of a ladder
diagram A ladder consists of individual rungs which
contains one or more inputs connected to it and one output.
The first step on a rung is to check the input instruction and
last will be always the (or its equivalent).
Figure 6:-Ladder Diagram
Notice in this simple one rung ladder diagram we have
recreated the external circuit above with a ladder diagram.
In this Circuit we used two switches SW1 and SW2, for
loading the instructions. At the end of the rung there will be
a output Coil. Different manufacturers use different output
instructions for executing the outputs. Different PLCs also
require an end instruction on the rung after the end rung [5].
V1. PRESENT THEORIES & PRACTICES
Originally they were designed as a replacement for
hard-wired relay and timer logic control systems. PLCs have
the great advantage that it is possible to modify a control
system without having to rewrite the connections to the
input and output devices, The Program in Plc can be stored
in battery backup memory only. Unlike other equipment’s
General purpose computers, the plc is well designed and
manufactured for extended temperature ranges, immunity to
noise, and is mechanically more rugged and resistant to
vibration and impact. By implementing this project we will
decreases the man power, hence will increase in production
of the industry [4].
PLCs can be compared to computers/Pc but have more
advantages and functions as compared to the controllers
1. PLC is more immune to noise vibrations temperature and
lusty condition.
2. The interfacing for inputs and outputs is the controller.
The plc is well designed and manufactured for extended
temperature ranges, immunity to noise, and is mechanically
more rugged and resistant to vibration and impact. If it want
a device in a PLC system to behave differently or to control
a different process element, all have to do is change the
control Program Earlier Human controls the crane & that
passes through large drawbacks such as more numbers of
wires required, large faults will be there and many more
difficulties in troubleshooting & repair work .Due to these
Drawbacks the production suffers a lot and hence growth
decreases rapidly. This is the main reason in order to remove
irregularity of relays and wiring issue we prefer PLC to
control and monitor the operation of crane in the industry. In
future definitely PLC is dominated on all other controlling
methods.
References:
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Based Re-Implementation Concept for PLC Programs and Its
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and Syed Jaad UI Haque.,”Industrial Data Acquisition and Control
System using two PLCs’ Networked over MPI Network”, 2009
IEEE symposium on Industrial Electronics and Application
(ISIEA2009).
[3]. S. Da'na, A. Sagahyroon , A. Elrayes, A.R. Al-Ali, R. Al-Aydi,
“Development of a monitoring and control platform for PLC-based
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