Mini project

P.E.S COLLEGE OF ENGINEERING, MANDYA

(An Autonomous Institution under Visveswaraiah Technological University, Belgaum)

Mini Project Report

On
“Motor interlocking using switches”
Submitted for partial fulfillment of the requirements specified for the award of the
degree in
Bachelor of Engineering
In
Electrical & Electronics Engineering

Submitted By

SL NO STUDENT NAME USN

01 SANTHOSH A K 4PS21EE039
02 AMBUJA H M 4PS22EE401
03 NANDINI B S 4PS22EE405
04 SOMASUNDARA K P 4PS22EE413

UNDER THE GUIDANCE OF

SUKANYA H N
Assistant Professor,
Department of Electrical & Electronics Engineering,

Department of Electrical & Electronics Engineering

P.E.S COLLEGE OF ENGINEERING
Mandya – 571 401
2023-2024

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P.E.S COLLEGE OF ENGINEERING, Mandya – 571 401

(An Autonomous Institution under VTU, Belgaum)

DEPARTMENT OF Electrical & Electronics Engineering

CERTIFICATE

Certified that the project work entitled “Motor interlocking using switches ”is a genuine
work carried out by SANTHOSH AK ,AMBUJA H M, NANDINI B S,SOMASUNDARA K P. bearing
USN 4PS21EE039,,4PS22EE401,4PS22EE405,4PS22EE413 a bonafide students of P.E.S College of
Engineering, Mandya, in partial fulfillment for the award of Bachelor of Engineering in Electrical &
Electronics Engineering of Visvesvaraya Technological University, Belgaum during the academic year
2023-2024. It is certified that all the corrections/suggestions indicated for Internal Assessment have been
incorporated in the report deposited in department library. The project report has been approved as it
satisfies the academic requirements in respect of project work prescribed for the said Degree.

___________________________ _________________ ______________________

(Signature of Guide) (Signature of HOD) (Signature of Principal)
Sukanya H N Dr.Mahesh kumar K M DR.H M Nanjundaswamy

External Viva

Name of the Examiners Signature with date

1)

2)

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ABSTRACT

A Programmable logic controller (PLC) is a type of industrial computer designed to control

industrial equipment and processes such as motors, assembly lines and processing and handling
machinery. Designed to be rugged to resist harsh conditions, PLCs are ideal for control applications
in environments that experience high levels of dust or moisture, vibration, shock, and extreme
temperatures.

Motors are widely used in industrial applications, and PLCs are an ideal solution to control them.
They allow complex rules to be easily implemented: for example, when a start button is pressed, the
motor should start only if sensors show that safety guards are present and there are no error
conditions.
The project involves designing and integrating various components, including programmable logic
controllers (PLCs), sensors, actuators, and human-machine interfaces (HMIs). These components
work in unison to create a cohesive system that can perform the desired task with minimal human
intervention. The PLC serves as the central processing unit, executing pre-programmed instructions
based on inputs from sensors and controlling actuators accordingly. Sensors provide real-time data
on parameters like temperature, pressure, and position, ensuring the system respondsdynamically to
changing conditions. Actuators, such as motors and solenoids, perform physical actions required to
complete the task. A crucial aspect of this project is the software development that enables seamless
communication between hardware components and facilitates user interaction through the HMI. The
HMI allows operators to monitor system status, input commands, and receive alerts on any
anomalies, ensuring the system operates smoothly and efficiently.
The project's outcomes include a detailed analysis of the system's performance, highlighting
improvements in production speed, accuracy, and overall operational efficiency. Additionally, it
underscores the potential of industrial automation to reduce human error, enhance safety, andlower
operational cost.

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TABLE OF CONTENT
SL NO CHAPTER PAGE NO
1 Introduction 05-06
2 PLC 07-09
4 Block diagram 10-12
5 Methodology 13-14
6 Hardware description 15-18
7 Flowchart 19
8 Result and discussion 20-22
9 Conclusion 23
10 References 24

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CHAPTER 1:
INTRODUCTION
PLC is an industrial controller based on a microprocessor. It has a programmable memory used to
store program instructions and various functions. A PLC collects data from sensors or other input
devices, processes this data according to its set parameters and then generates appropriate outputs.
These outputs could be commands to start or stop a machine or set off alarms to warn that a process
has strayed outside its limit values.
A PLC consists of five major components:

Processor unit – this interprets the inputs, executes the stored control programme and sends output
signals.
Power supply unit – converts AC voltage to DC.

Memory unit – stores data received from the inputs as well as the programme executed by the
processor.
Input and output interface – used by the controller to receive and send data from and to the external
devices.
Communications interface – receives and transmits data on communication networks to and from
remote PLCs.
PLCs are easy to program , even by people with little experience of programming languages. The
most common method is a graphical programming language called ladder diagram. PLCs also offer
high reliability and easy fault diagnosis for processes.
They replaced hardwired relay-based control systems, which were time consuming and difficult to
design and troubleshoot. Despite the advent of more sophisticated control systems based on standard
computer hardware, PLCs remain popular for their rugged construction and ease of use.

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PLCs do not control motors directly. Rather, they provide an output signal to an intermediate device
such as a relay or variable frequency drive (VFD), which commands the motor to switch on.
PLCs are in effect highly flexible industrial computers that can use a wide variety of input and output
signals. These can take two forms, discrete or analogue signals. Discrete signals can take only an on
or off value from devices such as limit switches, sensors and encoders.
Analogue signals can use voltage or current that is proportional to the variable being monitored
and can take up any value within their scale. Input parameters using an analogue signal include
pressure, flow rate and weight.
Discrete signals are the most suitable type for simple motor control. In most cases, operators will
only need an on or off command to be outputted or to read the status of a sensor that determines if
the motor is safe to operate.

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CHAPTER 2:
PLC & LADDER DIAGRAM
 A Programmable Logic Controller (PLC)
A Programmable Logic Controller is industrial computer control systems that continuously monitors
the state of input devices and make decisions based upon a custom program to controlthe state of
output devices. It is designed for multiple inputs and output arrangements, extended temperature
ranges, immunity to electrical noise, and resistance to vibration and impact. Almost any production
process can greatly enhance using this type of control system, the biggest benefit in using a PLC is
the ability to change and replicate the operation or process while collecting and communicating vital
information. Another advantage of a PLC is that it is modular ie. you can mixand match the types
of input and output devices to best suit your application. A programmable logic controller (PLC), or
programmable.

FIG: BLOCK DIAGRAM OF PLC

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 PLC languages:
1. Boolean Language or Instruction list
2. Sequential flow chart
3. Structured text
4. Functional block diagram
5. Ladder logic diagram

 Types of PLC:

1. Fixed type plc: It is used in micro scale industry, in this type of PLC input and
output are fixed .it has 128 no of I/O’s.
2. Modular type PLC :In this type of PLC we can extend the input and output to
maximum range hence it is used in medium and large scale industries. Totally it
has 2048 no of I/O’s.
3. Rack type PLC : in this type of PLC base module will be small and the extended
module will be arranged in Rack . it is used in the Large scale industry only. We
can extend the range of input and output up to 16,000 I/O’s.

 Specifications of PLC:

1. PLC – Delta
2. Model- DVP24ES200R
DVP- Delta virtual panel
24- total no of I/O’s
ES200- series
R- type of output in relay
3. PLC type- Modular type plc
4. Supply voltage -230v AC
5. I/P ofr O/P voltage- 24vDC
6. No. of input-24
7. No of output-8
8. No of communication ports-3

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Ladder Diagram

It is a graphical programming language, initially programmed with simple contacts that simulate
the opening and closing of relays. Ladder Logic programming has been expanded to include
functions such as Counters, Timers, shift registers and math operations. Ladder logic is a
methodof drawing electrical logic schematics. It is now a graphical language very popular for
programming Programmable Logic Controllers (PLCs). The name is based on the observation
that programs in this language resemble ladders, with two vertical "rails" and a series of
horizontal "rungs" between them. A program in ladder logic, also called a ladder diagram.

FIG: LADDER DIAGRAM

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CHAPTER 3
BLOCK DIAGRAM

MOTOR 1
PROGRAM
LOGIC
CONTROLLER
MOTOR 2

MOTOR 3
SWICTHES

MOTOR 4

MOTOR 5

MOTOR 6

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CHAPTER 4

Methodology
1. Project Planning

Define Objectives

 Automate the control of machines using switches.

 Enhance safety and efficiency in machine operations.

Scope Definition

 Identify the specific machines and operations to be controlled.

 Determine the types of switches (e.g., push-button, toggle) and their functions.

Resource Allocation

 Determine hardware and software requirements.

 Assign tasks to team members.

2. System Design

Component Selection

 PLC Selection: Choose an appropriate PLC model based on the number of I/O ports
andprocessing requirements.
 Switches: Select the types and quantities of switches needed (e.g., start, stop,
emergencystop).
 Machines: Identify the machines to be controlled and their control requirements
(e.g.,motors, conveyors).
 Other Hardware: Select necessary relays, contactors, power supplies, and wiring.

Input/Output Configuration

 Define how switches will be connected to the PLC input ports.

 Define how machine control elements (e.g., relays, motors) will be connected to the
PLCoutput ports.

System Layout

 Create a detailed diagram showing the placement and connections of all

components,including switches, PLC, and machines.

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3. Programming the PLC

Development of Ladder Logic

 Write ladder logic or another suitable PLC program to control machine operations
basedon switch inputs.
 Include control logic for starting, stopping, and emergency stopping of machines.
 Implement interlock and safety features to prevent accidental or unsafe operations.

Simulation and Testing

 Use PLC simulation software to test the control logic.

 Debug and refine the program to ensure correct operation.

4. Hardware Setup

Installation

 Install the switches, PLC, and control elements at their designated locations.
 Ensure all components are securely mounted and protected from environmental factors.

Wiring

 Connect switches to PLC input ports according to the system layout diagram.
 Connect machine control elements (e.g., relays, motors) to PLC output ports.
 Ensure all connections comply with electrical safety standards.

Power Supply

 Provide an appropriate power supply to all components.

 Ensure backup power solutions are in place for uninterrupted operation.

5. System Integration

Uploading the Program

 Upload the ladder logic program to the PLC.

 Configure PLC settings for optimal performance.

Initial Testing

 Conduct initial tests to ensure all components are functioning as expected.

 Verify that machines respond correctly to switch inputs.

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6. Testing and Validation

Functional Testing

 Test the system under various operating conditions.

 Verify correct operation of switches and machine control elements.

Performance Evaluation

 Measure response times and accuracy of the system.

 Validate the system’s ability to handle normal and emergency operations.

Debugging and Optimization

 Identify and fix any issues discovered during testing.

 Optimize the program for efficiency and reliability.

7. Deployment and Monitoring

Full Deployment

 Activate the system for live operation.

 Monitor the system closely during initial deployment.

Maintenance and Updates

 Schedule regular maintenance to ensure ongoing reliability.

 Update the PLC program as needed based on operational changes or
systemimprovements.

8. Documentation and Training

Documentation

 Create comprehensive documentation for the system, including hardware setup,

ladderlogic program, and maintenance procedures.

Training

 Train relevant personnel on system operation, troubleshooting, and maintenance.

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CHAPTER 5
Hardware Description:

CIRCUIT DIAGRAM:

MCB:
MCBs are electrical protection devices that automatically switch off the power supply to a
circuitwhen an overload or short circuit occurs.
USED: C6 MCB

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Rectifier:
A rectifier is an electrical device that converts alternating current (AC) to direct current (DC).
It isa crucial component in many power supply systems, including those used in fire fighting
systems.

Push button:
Momentary Push Button: Returns to its original state when released.

Off switch:
An off switch is a type of electrical switch that is used to disconnect power from a circuit or
device.It is typically used to turn off a device or system when it is not in use, or to shut down a
system in case of an emergency.

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Programmable Logic Controller (PLC) :

A Programmable Logic Controller (PLC) is a digital computer used for industrial automation
and control. It is designed to monitor and control industrial processes, machinery, and
equipment. The PLC used in this project is the Allen-Bradley MicroLogix 1400, a high-
performance controller thatoffers advanced features and flexibility

USED: DVP14SS2 PLC SPECIFICATIONS:

PLC: Delta
Model: DVP14SS2
PWS voltage=24V
DC I/O Voltage=
24V DC No of
inputs= 8
No of outputs=6
No of communication
port=2 PLC Type=
Modular

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8 Channel relay:
An 8-channel relay is an electrical device that allows you to control eight separate circuits
ordevices using a single input or signal. Here are some key details and descriptions:

Key Features:
2. 8 individual relay channels
3. Each channel can handle a separate circuit or device
4. Can be controlled using a single input or signal
5. Typically uses electromechanical relays or solid-state relays
6. May have built-in protection features like overcurrent, overvoltage, or thermal protection

Indicator light:
Indicator lights, also known as pilot lights or status lights, are visual signaling devices
thatindicate the status or condition of a system, process, or equipment.

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CHAPTER 6

FLOW CHART

START

END

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CHAPTER 7:

LADDER DIAGRAM

COMMENTS:

INPUTS :
S1=Switch 1
S2=Switch 2
S3=Switch 3
S4=Switch 4

OUTPUTS:
Y1= Motor 1
Y2= Motor 2
Y3= Motor 3
Y4= Motor 4
Y5= Motor 5
Y6= Motor 6
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Operation

• Switch 1: Activate primary motor 1& motor 1 (loads 1, 2).

• Switch 2: Activate secondary motor 2& motor 2 (loads 3, 4) and deactivate primary motor1&
motor 1 (loads 1, 2).
• Switch 3: Activate motor 3& motor 3 (loads 5, 6) and deactivate all motor 1&2 &motor
1&2 (loads 1, 2, 3, 4).
• Switch 4: Activate all motors & motors (loads 1, 2, 3, 4).
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CHAPTER 8
Results & Discussion
Result
1. Increased Efficiency and Productivity:
Automation of Repetitive Tasks: PLCs (Programmable Logic Controllers) are instrumental in
automating repetitive and monotonous tasks, resulting in significant improvements in production
efficiency. Minimized Downtime: PLCs can quickly identify and diagnose faults, reducing
downtime and ensuring smoother operations.
2. Enhanced Flexibility and Scalability:
Programmable Nature: PLCs can be reprogrammed for different tasks, providing flexibility in
manufacturing processes. Modular Design: PLC systems can be easily expanded or reconfigured to
accommodate new machinery or production lines.
3. Improved Quality Control:
Consistent Output: Automation ensures consistent production quality by minimizing human error.
Real-time Monitoring: PLCs offer real-time monitoring and control, enabling immediate
adjustments to maintain product quality.
4. Cost Savings:
Labor Cost Reduction: Automation reduces the need for manual labor, leading to cost savings.
Energy Efficiency, PLCs optimize machinery operation, often leading to reduced energy
consumption.
5. Data Collection and Analysis:
Comprehensive Data Logging: PLCs can collect and log data from various stages of the production
process.
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Discussion
1. Technological Advancements:

Integration with IOT: The integration of PLCs with the Internet of Things (IoT) is transforming
industrial automation by enabling more sophisticated data analysis and remote control.
2. Challenges:

Initial Investment: The upfront cost of installing PLC systems can be high, particularly for small
and medium-sized enterprises.
Skill Requirements: Operating and maintaining PLC systems require skilled personnel, which canbe
a barrier for some companies.
Cyber security Risks: As PLCs become more connected, they are increasingly vulnerable to cyber-
attacks, necessitating robust security measures.
3. Industry Applications:
Manufacturing: PLCs are widely used in the manufacturing sector for tasks such as assembly line
automation, quality control, and material handling.
Energy Sector: In power plants and renewable energy installations, PLCs control processes to
ensure efficient and reliable operation.
Automotive Industry: PLCs manage robotic assembly lines, enhancing precision and speed in
vehicle manufacturing.
Food and Beverage: Automation of packaging, processing, and quality control in the food and
beverage industry relies heavily on PLCs.
3. Future Trends:

Edge Computing: The adoption of edge computing in PLCs is expected to grow, allowing real-
time data processing and decision-making at the source of data generation.
Sustainable Automation: Developing more energy-efficient and environmentally friendly PLC
systems aligns with the global push towards sustainability in industrial operations.
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