Working Wlth HMI software Tool .

J 2
s 2 2 2
• Configure PLC wllh HMI • Pradk• HMI pn,grammtng lnwlYln,
• Anlffl.1tion with graphtral ol,f«ts alarms. trfflds and bar ,npfd
• Animate obfects on an HMI SCl'ftn to
monitor motor 5bt1IS
• Trrnd tM cbta of ;a process p;[Link]~rr
using a ~nd tool
• Ctta~ Us« groups and monitor
proJ>@r authentication.
SO'ftftS with
• u~ security featurn to do tag togging
and command txttUtion
2 s
5 3 • Practice control or a Motor through HMI

s 4 Su~rmor y [Link] control and acqubition . Practke control of a Molar throup SCADA
I l'
system (SCADA}
software
• Concepts of SCADA systfflls
• SCADA hardwarr
l Field ffll Instrumentation and
control devices
lL RTU· Remote tft'fflirw unit
liL Commun1a tJon systems
Iv. Masttr (Ontrol Sl3tlOn
Y. Data processlna ,omputff
systems
Yl Cttatlng and Editing tax
YiL Cttating Graphs and bar [Link],
Abnn conncur3tiOn, Tttnd.s
(Rn! tim~ and Historical).
Report genft"iltion
• ·SCADA Protocols
• Aooliation of SCADA Acc,,,canf"t lt R,lvl,-w a11d t'ftll't"H'tlwi ~ >
s n.w•lftrM Htbl w..kty Aeu>teCM•nt
6 Industry Class oa HMI and SCADA + 5
lndmtn Asslmment \

; 3 1 PEER Dlsaasaon OD Industry AssiRa... nt 4 Problem Stal••Ht: Botti~ fUU ni h.1s ~ const:lnt 1 2
soccd of fiUiM 20 bottles ocr minute. nus m«d
d•ncls on ~ or aw tank dH • tu lwal
pffSSUt t. To malntaffl this spNd. prtSSUf f twad of
t!w filing tank ha to~ matnutMCI at a parllalfar
Intl lmpktnwnt this aoloma tioll tn PLC using
l.:Mid,i,r rn.,-.-rn ~""" Int t.:1ng, ~

D~~ :
' t·
!
.!
t:l
SJ
t,.'";;J

Cond,l tlon: To continuously maintai n constan t

Prt>SSure In tM tank

l) For th~ abott ~ - D1scuss tM sultab~

s~nsor ~[Link]. PLC. DriwS.
Cnmm un~tin n Pmtnnd ~ A~l:at.d
1lardware compont'nts

U) ~lect [Link]~ compoM Dts from th~

Company atal ~ and rKOrd thdr
sp«trta tions In a DATA Shttl

Ui) Dewlop a PLC uddtt Program for tlw .

abov~cas~. slmul~tr-. lntfff~ « with PLC
and HttUtt '

tv) D·[Link] thtt Appllattons of the above-

Cas~
-
-- 3 2 Pntblem StatflMftt: A ~ drops matttlal on~ conveyor which wnds [Link] for fu11h@I' ~ through 2
~ mott conveyor. ConW)"Or [Link] automatically whffl materbt Is droppftl on It. lml)lftnnt automal1on of
s
this ln PLC using [Link]« Diagram programming language.

Oiacram:

-r.,
-
......-r ;:.L,_t;;

~ - -;;. _, ,'

-·
r,n nclJtlmt!
• Feeder has a motor mounte d lo feed material on conveyor belts.
• Load cells are Installed at the bottom of conveyor belts to detKt if materbl Is p~nt on the con'R)"or
belt.
• When ffl3leri3l falls on conveyor Mil t . motor 1 should [Link]. ilnd whm m3teri3l in prM~nt on co.n,."f!yor
M-lt 2, motor 2 remain On.
• Switcht-S an also be used sottH!'times to dett'ct matuial's pre~ntt. But for mote reliable- opel'3tion. Load
cells can be used as shown ln the diagram abovr

a) For the- above~. Discuss the sulubll' sensor technology~ PLC. Drivt!S.• Communication Protocol [Link]
Related Hudware components

b) Se-Leet Hardware components (rom the Company caulogue and record thrir specil1G1tions ln
3 DATA Shttt
, f c) l>Pwlopa PlC Laddtt Plogaa.n rot~ a~Cdf. f ~ . tnt,rf.x~ wflb rt£ andftllrllW

dl Oisnm tM Anolirations ol tM aboY~ (:asp

3 3 """'"" [Link]: Parts .1R mov1,.. on thtt tollftJOI' (rom OM prOttSS 6M toodwr wtrh a ([Link]~
Out of 1000 part one pert b takc-n out for quality ch«IL fm~mt'nt •U'lDIUdon ~dab In PLC_,..., £addn'
Diagram fNO,laturting l a ~ .

fl~III!

CondJtJon:
• To detect~ p.;utt. dettetor such as proxhnlty switch. [Link] ~nsors or-any~r~nsorls used.
• r.,..nn,ort nutpot n/ rhi< d,,,tprtnr rn fnpur [Link],. nl Pf I. whim <fl•~ :and n-<#t< ~ ,n,-,nmy :arrn,yjirte rn
JJ,UU' drt«UutL
• Give thJ.s detection, as. an Input to Up Counte-r which Js intnme-nted with each part's d ~ A
• 5ft counter p~t value to l 000.
• Operate Solto-noid for a f~ seconds until the part is divertrd for [Link] check.

a) for the .above [Link], Discuss [Link]' suitable- ~nsor ttthnofogy. PLC. Drives. Commu-nlca:Uon Protocol and
~ Kardwa:re components

b} SelectUardwarecompoMtttSfromtheCompanycatafope-a ndrwordtheirScpttirtcationslnaDATA~

c} Develop a [Link] fordu~abowcase,slmubtt,lnterfau-wfdt Pl.C~ n-KUtt-

d J Discuss the A1>1>[Link] of the above Case

4 Prohle-m Slalffllfflt: Afttt filli~ prncns, bot~s a~ mond on w ronv~ ~It for [Link]« prouss. Dd«t 1r 2 s
any ffllpty bot~ ts ~ on lht l'Ollft)'Or and ~fflOft u from tht convryot. fmp1•mtnt a u , ~ of dtlS In PLC
using [Link] Diagram programming bnguag•.

t@?t!t!i?t?i!!!f!t!I~
~ ~

Condition:
• Proximity sensors are usNl to dttttt bottJes.
• 0n,- rm1rlmiry k r.1lihr.1tM <ttr h t tur It di-t Hf< aU th,. h«mlP< f\:.\~dn& nn th.- mnw,ynr. Anrl nth#r
p1 uxlmlty b u~ ~ud, LILll fl J elab uuly t"ltll)ly w ult-.
• u~ BU Shirt Rtgister to shm a bit which Is set when an empty bottle Is d~ttted
• u~ a PMumatic Cylinder or blower to throw an empty bottle out of 1M conv~r
al for the above case. Discuss the [Link] sensor technol()JO', PLC. DrittS. CommunJation Protocol i1Dd
Related Hardware components

b) ~«t Hard wart' components from the Company catalogue and reconl thtilr spedfkations tn a DATA ShHt

c) Develop a PLC Ladder Program for the above case, simulate, fntcrfatt wtth PLC and c-xccutc

dl Discuss th• Ar>01icatlon-s of the above Case

5 OE 2- Written and practice tnt I I I I [Link] Review and corFKtlve anion 3
 Oass . . Awt oma tton In lndUSlTJ' ♦ s 1 I I
hld tiU j
I ... .• •- ""' mrn t
' 16 on 11w
Ptol tl.m Stat ftllf tlt: Part s att mow d 1
«t.d
al
4 con n,or . Cou nt th@ numbft- of parlS a,n by
[Link] it ontM dhp
tM@nd of lh4!t ~nw ,yor and nmm lng
In PLC ust ,. Lad dtt Diagram pn,g
language.

Dlap-am:

()
', r

ent
PEER Disc ussi on on Ind ustr y Ass ignm Con dJd on:
• Mnn nt Pnw imit y Swlt rh tn d.t. -rt th.-
JMl l.5..
an
• Use outp ut of prox imit y to cou nter as
Inpu t to Incr eme nt data
• Convert this num ber into app mpr la~
[Link] 3nd sho w num ber of [Link] s
collected.
Use Indu ctiv e or up. Kit i~ Prox imit
y
•
Non-
swit che s are ~~R ilin g o.n Met al or
Metal
•
u,~ ~i~ ur
[Link] lltb ~t!ll WI Jl.l.U l dill)? lu
part s pres ent on ~ cun ~yo r and wid th of
conveyor so that this st'n sor can det ttt
part s easily.
• OJP is ~d to lnc n~ t the num ~r of
_pmis coll tttcd .
 a) Fortt..~[Link]- Nltlllle
SfflSOI' l«llnalogy. PLC,, Ortws.
Communlallon l'nltoml and --.._.
Hai dw.-c aMDpoM:Dtl

b) ~ lbnlwaft a,mpaMfflS hna Ille'

Company ~ and l'fflJnl. dmr
~[Link]

c) Dewlop a PLC ~ Program for 1kt

aboff case. shnubt~ lnterbtt wlda PU:
and~

dl Discuss 1M Annlk-2tions of tR abow Case

3 2 Problem Statement; Diffttfflt obj«ls att mcwiftgon amnwyor belL Lds say. [Link] blodcs and 2 !
~ blodcs. All thrtt types ofobf«ts are collected In the saJM ~[Link] lbest! types are diffffent in
size and shapes as lffll. number of obj«ts to be placed are dUffffflt for nch tJJW. Set cowattt~ amndkag to
different sized obtms• d ~ . lms,lftnffitautomatlon of dm In PLC u s ~ ~ r Dia#,lm l)l'OOallUllm,t
Ian~.

( -~ ~~~~-$$iNA!l!i~fF,il1(~:"'~''~
-' ~ ~~~~~~f!i~~l~$9~:ffl.~~~~'.r::",,
, ,
~
~: )

• •• 1,
k ~ U
~ Iii ~itt
n 11-~n11
[Link]:

• u~ thtff cliffermt proximity switches to d~tKt all thl'ff diffettnl obt«ts.

 • Mount thne switch@! such that switchM detect assf~ned o~t only. For examJJlf, mount Squarl!
det«tor proximity such that It nrith,r delKts R«tangubr blocks nor Balls.
• Load c:ounter va1ue-s In ~ M ' S for different obf«ts. And toad this value ..s soon a~ a particular
type of object ts d~emd.

a) For~ above cas~. Discuss th~ suitable sensor trchnoloJtY. PLC, Drives. Communication Protocol
and Rebt-N Hardware componfflts

b) Select Hard~tt components from the Company catalogue and tteord their .specifications In a
OATAShttt

c) U~lop a l'Lt: Ladder Program for the above case. [Link]. lntedac~ with l'U: and necute

d Discuss the A Uations ohhe above Case

3 3 Problem Statem~nt: Objects are moving on a conveyor belt l . When an empty box is detected. roiweyor bt!lt 2 s
starts and Spcs are pack~ In a box. Wh~n box is fill~, it l~ carried to the storage area via conveyor belt 2.
Lmplement auto [Link] of thls process in PLC using Ladder Diagr:am programmf ng language.

~ ) .._,. I ~

If</

I~
i lf H 1

[Link]:
 Diplom a ln Mtthan kal £nglnH ring IC 10 '20'10 • 21
• U~ proxim ity SWltchH to detm moving ob)Kts on~ m-nvey
or belt 1 and to ck1ffl an empty bos Oft
~ heft 2.
• U~ counte r to count numbt! r of objKts to b. packed.
• Uw tiffll!-r Std that when Spa are detert@d. conveyor runs for
a white and ~ [Link] 51h oblftt ~
finally coll ~ In the box. Assum e time by calculatina; convey
or belt s,,nd.
• Wltftl numbe r or parts to be p;ac:ked a~ d~tected lirMr '5 actlvat
ftl ~ limtt Is O¥tt, It $tQP$ the
c o ~ until nnt ffl\pty boll ls dettct.e d.
• Assum mR [Link] ukm by the last Sth obl«t Is 2secs to be collec
t~
a} For the abow case. Discuss the suitabl e HMOr 1Khno1
ogy. PLC. Drives. Conummlcation Protocol and
R~~ Haniw an- compo nents

b) SeftttH ard:wu ecomp onmtsf romthe Compa nyatal oguean

dreico nllhe:t rspedf 1Catk> nsmaD ATAS heet
c) ~ p a PLC udder Progra m for the abov e~. simula
~. lntmx e w\th PU: and ettCUl e
d Discus s the A liotion s of the above Cas~
3 4 . Problem Stakm ent: ~nev « a part ls placed on the drilling
table. pneum atic cbnrpe r damp s.~ pan: and.
drillin g proces s ls done. On comple tlng the drilling proces s,,
lhecb npen~ leases the partby mn sm g~
When ano~ r part Is detrct ~. the proces s Is repcate d. lmpl
~nt this in PLC usin«, bdde r Di~m
progra mming langua ge
Df4f'il ll:.

Condi tion:
 • Set 1o'Wft' and Upptt limit of a motor to stop [Link] th~ drilling prottSS. This Is don~ for ~ drflling
and to obtain unlformny.
• Pttssure opN"a~ damping d ~ is .~ to hold RM objttts firmly. This Is opH3lt"d by air supply whkh
is pt"O\'ided wh-e11 an obj«t is d'e tected.
• Umit detection objKt is placed on the- motor to detttt 1:i~r and lower limit by dw! switchH.

a) For Ult"! ahovr cast!'. Discuss th~ suita:bl~ smsor technology# PLC. DriYH,. [Link] Protocct and
Related Hardware compon~nts

h) Sdect Hardware compoDftlts from the Company catalogue and record thdrspKiflatlo·n s ln a DATA [Link]

c) ~ o p a PLC Ladder Program for the- .above-use-. simulate-. lntc-rf~ with Pt.C and encu:te

.d} Discuss the Aoolications of the abov~ CilR in othtt m;1ehlnn

5 Dt!Rlnpmental w~ ~smfllt · Assessnmat [Link] 3
6 Industry Gass on Trends In Automation+ S
lndustrv Asslmun~nt
1 Probl~m Sl:at!Plllftll: lmpmnent autcmatitm to 1
control Continuous Stim~d Tank Reactor of a.
4 irhf"[Link] pint in Pl.C ,~ng [Link].d""" m~a-rnm
PEER Discussion on Industry Asstgnml!llt pn,grammlng bngu:l~

Dbl!l"am:
 ___ ·--
....... .
,
...
--
_.....··-·--- ~ ~

.--~-.....-
-- ,,...,
~

.-
______..: .--
......-

CondJUoa:
• Thr tt par.a mt-tt tS arr cont rolW In Ibis
[Link]. Tm, pttat Utt. Aow and ~• of
th~r ank
• Us~ PIO Con troll tt
For the At>c>ff case. Drv et
pn,t ,fna Slat. e men t: \Vat rr bott l~ are mov M on a conv m
2 eyor for capp in~ 5cttW caps are scttW ed s
np-n int f'lftd nf rh,., hnfrf,i. u~ing rnt:rt to cl~ the 2
ing m~ niu n. rmrt.-m41ttt thioe in Pf.C:
tr<in g J~f l'r m~ m rrngr ::am mine
t.a,gu..g~
 Condition:
• To ~nse the bottle. proximity ~nsor is uwd.
• Used a U~r to stop the cylindN" motor for 2s«s to scttW caps.
• Used one mon- limer to run the motor for 1SK to rotate the cylindtt.
• Bit Shift re,tister is also used to perform [Link] operation .
• Count the num~r of steps capping rmchlne ls pbced from the sensor 2nd Rt blt
pmkk>n to Dpff3te
capplnt m.1chlne accordini lv.
• In this examp~ as you an Stt. bottle ls 7 steps away from ~ proximity switch. so
if Bit Rgisttt 83:0 is
~d. lhen c,ppin2 m3chine should~ operated ·when 83:0/0 is [Link] to 83:0/6.
• Two Inputs are ctwn to this Cappinc machine. electric supply to run motor and pMUmati
c supply to push
machine down cap ram.

a) For the above~ . Discuss the suitable Hnsor technology. PLC. Drives. Commun
iation Protocol and
Re-lated lbrdware components

bl Sel«t Hardware componen ts from the Company cat11oiue and r«ord ~ir spttificat
ions ln 3 DATA Shftt
c) Ot'velop a PLC Ladder Program for the abo~ case, simul3te. lnltrfa~ with PLC and
necute
d Discuss tM A licaUons or the above ase
Departme nt or Col~te & Ttthnial Eduatlon Beni,a
3 3 Preblnn Stat.l'nf tlt: Two tanks hJw sarM produru fillttd. Drainlnt! from tht'H
lhtt sto~ bnk. lmplttmmt autom:1Uon in this Dralnagtt bnk using with PLC using
~ncls on thtt reqvtrffl wnt from 2 s
Ladd« Diagram prognmmtng
bn~
Diagram:

Condition:
• Lrvel [Link]?e ts ust'd to fflt"aSUtt lewl of the storage tank continuously
• Lcvd gauge b connected with Lc-vd Transmitter which convert:, correspo
nding level output In 4 20rru\
ttqui~ L
• Analog 1/0 Modul~ att chosen to dt'al with Analog signals.
• Pumps ~ u~ to drain material from both thr tanks .at thtt samr lime.
• Two low level switches a~ used to d!tl'ct low ll'Vl'l or unks 1 and 2 which turns
Pumps OFF "'bttn low
levrl is tt.1chNf.
• Height of storage tank Is Smtttt>rs that is 500cm and tht' lt'ttl which ls to be
maintli n~ ls 470cm.
~, ..-or tht' ab<Wt- ~ . VIMU$$ lht' $Ulbblt' $t'J1$0r lt'thhot ~. I'll. UrivH. Commun
ltatton l'rotoc:ol and
Rdatcd Hardware components

bJ Sel«t Hardware components from thr Compan ycaulog ue and rt'COrd tht'irspe
dficltion s [Link] OATAShttt
c Ocvdo a PLC t..,ddcr Pro ram for the obove Cil:iC', ,lmul,Ue, lntcrfacc with PLC
and c-xccutC'
 d} Discuss the Applications or the aboff Case

3 4
Problem Statem ent: Potato chips att made and re.-ady to be packNL 2 s
But Mfott t.h3t. lt gon through a convey or
in whkh final quality chtck Is done. burnt chips arr ddectN f and ttmow
d from the prottSS line. lmp~m-t-nt this
ln PLC uslnt Ladder [Link] p~ram mlng lan.,a.a,:e

Dtapanm ~nf of rn
 DlaBHt:

81..nwdchipa

l
L

t<

[Link]:
• Tn ,f,tprt hurnNf rhlrc.. [Link] c;nur,,. :uvf c,onc;nrc. ;ar,. [Link].
• Ughl suu1 ti!' is uSL1.I su tigl1l detatu,s sud1 ~ Light Dt!JJt!Ulh!out Rtc"Slslul5. .11 e USt!d tu delftl Ure
burned chips.
• Blowers .ue used to throw burned chips ;away from the conveyor when d ~ &
• There are total number of 8 blowers. Numbe-r of blowers to be used depends on the width of a
(u11v~yu1 ln~lt.
• Timr measurement of an e-vent to bier pbce can ~ used here to measure wh.-it time burned chips
take to reach from light source to blowers when det«ted.
• Set this time .u pre-ut of .1 timer to [Link] p;[Link] blower•
• There :ire 8 blowers. so 8 llght detecting drcutts must bt' ust'd tn ordt'r to op~te :all blowers.
• Lt't us 3ssume we are uslnc U.i:ht Dc-l)t'ndent Rrsistor. To use this rt'sistor, threshold h.1s to be set
that fs darkest color to be pasM:d as a good quality product. ff chips are darker than tM dnlred
level. H~ht source detects It .and activates corns.p ondin~ circuit
• So, outpu.t of th!li circuit ts normally high .and to activate- bloWC'r. normally low log le has to be set
while r ogramrnl ng or wt can tvcn lnnrt output from LOR circuit.

Oepartmfflt of Collegiate & Ttthnical Education Bengaluru-56000 1 [Link] 2S