MOTOR FORWARD REVERSE PROCESS USING PLC

A Project Report

In the partial fulfilment for the award of the degree of

B.Tech/Diploma

under

Academy of Skill Development

Submitted by

[Name of the student (s)]

[College Logo]

[College Name]
 Certificate from the Mentor

This is to certify that [Name of the student(s)] has successfully completed the
project titled [Project Name] under my supervision during the period from
January to February which is in partial fulfilment of requirements for the award
of the B.Tech and submitted to Department [Department Name] of [College
Name]

__________________

Sign
ature of the
Mentor

Date: dd/mm/2024
 Acknowledgement

I take this opportunity to express my deep gratitude and sincerest thanks to

my project mentor, SOUMYADIP SARKAR for giving the most valuable
suggestion, helpful guidance and encouragement in the execution of this
project work.

I would like to give a special mention to my colleagues. Last but not the least I
am grateful to all the faculty members of Academy of Skill Development for
their support.
 CONTENTS
INTRODUCTION

BASIC ELEMENTS

PLC ARCHITECTURE

INPUT/OUTPUT HARDWARE

ADVANTAGE AND DISADVANTAGE OF PLC

SOFTWARE IMPLEMENTATION

OBJECTIVE

LADDER LOGIC DIAGRAM (LAD)

CONCLUTION
 INTRODUCTION TO PLC

A Programmable Logic Controller (PLC) is a specialized computer used to control machinery

and industrial processes. PLCs are designed to perform a variety of control tasks in
manufacturing environments, including automation of machines, processes, and assembly
lines.

Key Components of a PLC:

1. Central Processing Unit (CPU):

o The brain of the PLC.
o Executes control instructions stored in memory.
o Processes input data and makes decisions based on the programmed logic.

2. Memory:
o Stores the control program (also known as ladder logic).
o Holds data and status information needed for operations.

3. Input/Output (I/O) Modules:

o Inputs: Receive signals from sensors, switches, and other input devices.
o Outputs: Send signals to actuators, motors, and other output devices.

4. Power Supply:
o Provides the necessary power for the PLC and its components.

5. Communication Ports:
o Enable the PLC to communicate with other devices, such as computers, other
PLCs, and human-machine interfaces (HMIs).

How PLCs Work:

1. Input Scan:
o The PLC reads the status of all input devices connected to it.

2. Program Execution:
o The PLC executes the control program, which contains logic and instructions
on how to respond to input conditions.

3. Output Scan:
o Based on the program execution, the PLC updates the status of output
devices.

4. Housekeeping:
o The PLC performs internal diagnostics and communication tasks.

This cycle is repeated continuously to ensure real-time control and monitoring of processes.
Programming a PLC:

PLCs are typically programmed using one of the following languages:

1. Ladder Logic:
o Resembles electrical relay logic diagrams.
o Easy to understand and widely used in the industry.

2. Function Block Diagram (FBD):

o Uses blocks to represent functions and logic operations.

3. Structured Text (ST):

o High-level programming language similar to Pascal.

4. Instruction List (IL):

o Low-level programming language resembling assembly language.

5. Sequential Function Chart (SFC):

o Represents processes as a series of steps and transitions.

Applications of PLCs:

1. Manufacturing Automation:
o Control of assembly lines, robotic arms, and conveyor systems.

2. Process Control:
o Managing processes in industries like chemical, oil and gas, and food and
beverage.

3. Building Automation:
o Control of HVAC (heating, ventilation, and air conditioning) systems, lighting,
and security systems.

4. Transportation Systems:
o Automation of traffic lights, railway signaling, and airport baggage handling
systems.

5. Utilities and Energy:

o Management of water treatment plants, power generation, and distribution
systems.

Advantages of PLCs:

 Reliability: Designed for harsh industrial environments with high reliability and
uptime.
 Flexibility: Easily reprogrammed to adapt to changes in processes and requirements.
 Scalability: Can be expanded with additional I/O modules to handle more complex
tasks.
  Ease of Troubleshooting: Provides diagnostic capabilities to quickly identify and
resolve issues.

PLCs play a critical role in modern industrial automation, offering a versatile and robust
solution for controlling a wide range of applications.

Automation
Automation is the application of machines for manipulating information as well as system
technologies (Kaushal,2015). PLCs have helped in improving the productivity of automation.
Raymond explains that the production of goods and services has increased production costs.
For manufacturing a commodity, according to Raymond, certain costs exist which the
manufacturer cannot control, these include labour costs, material costs etc. PLCs helps
automation by lowering the amount of power
consumed by working machines, controlling systems via proper keeping
of records and reducing required manpower via the supply of manpower. The programming
logic controllers (PLCs) have also helped lower automation maintenance. As regards this
(Siemens,2017), offered to analyse a situation where a corporation uses automated storage
and recovery systems for managing its warehouse. If a business uses trailing cables for
operating the automated storage and recovery systems, this will cause time wastage and
higher costs. The higher cost is due to the fact that these cables will need frequent
maintenance and replacement. Applying PLCs in automating these systems lowers
maintenance costs and also reduces needless downtime (Siemens, 2017). PLCs have been
effective in reducing automation downtime. Downtime means those periods when a
computer network or server is unavailable to users (Goel and Alok, 2012). PLCs are
becoming cheaper and smaller and yet increasingly powerful with time (Kaushal, 2015). Due
to its capabilities, PLCs are becoming more exclusive than conventional personal computers
and workstation arenas. The PLCs are now able to share data rapidly within and between
companies. This rapid data sharing has helped reduce downtime as PLCs are capable of
automating the FTP and web servers, international databases and even email sending. A
good instance is Java web servers which have achieved a high level of versatility in their
interactions with the PLC, thus enhancing data sharing and lowering down time
(Automation, 2017).

Automation impacts

Automation will increasingly impact the world of work during the next few years. This is
already felt in some industries, and different countries are experiencing the effects more so
than others. Discussions of how automation will alter working life, however, are always
loaded with ‘maybe’ statements.
Studies highlight varying degrees of job losses or job creation, yet scenarios are dependent
on factors that will facilitate positive or negative change. It’s not a simple case of the ‘jobs
we have now’ experiencing gains or decreases either. Yes, automation could create demand
for existing goods and services, but it may also lead to new industries and new jobs. Job
‘designs’ too could evolve once new technologies are embedded, and, if progress is positive,
there may even be more work to go around – or not, depending on what action is taken to
offset disruption.
Predicting the future is not a science. Differences of opinion vary. So, we’ve reviewed
research on automation and its potential impact on employment. We summarise our
findings below, including the steps required by governments and employers to ensure
positive rather than negative disruption.
Components of PLC

(1) Power supply: The power supply converts facility electrical distribution voltage,
such as 230 VAC, 120 VAC or 125 VDC to signal level voltage used by the plc
processor and other modules.

(2) Processor: The processor module contains the microprocessor that performs
control functions and computations, as well as the memory required to store the
program.

(3) Input/output (I/O): These modules provide the means of connecting the
processor to the field devices. Examples of these modules are Analog Input Module,
Analog output module, Digital input module, Digital output module etc. These are
used to connect devices between plc and field devices like flow transmitters,
pressure transmitters, control valves, analysers, substation feeders for motor control
etc.

(4) Communication :Communications modules are available for a wide range of

industry-standard communication network connections. These allow digital data
transfer between PLCs and to other systems within the facility. Most commonly used
modules are Modbus communication cards or Serial communication. Some PLCs
have communications capability built-in to the processor, rather than using separate
modules.

(5) Communication Media and Protocols: The most common communication media
used are copper-wire, coaxial, fiber-optics, and wireless. The most common “open”
communication protocols are Ethernet, Ethernet/IP, and Device Net. “Open” systems
generally provide “plug and play” features in which the system software
automatically recognizes and communicates to any compatible device that is
connected to it.Other widely accepted open protocols are Modbus, Profibus, and
ControlNet.

(6) Redundancy: Many PLCs are capable of being configured for redundant operation
in which one processor backs up another.

This arrangement often requires the addition of a redundancy module, which

provides status confirmation and control assertion between the processors. In
addition, signal wiring to redundant racks is an option.
Electrical Hardware
Electronic hardware consists of interconnected electronic components which
perform analog or logic operations on received and locally stored information to
produce as output or store resulting new information or to provide control for
output actuator mechanisms.
Actuation-
1.Manualy Actuation
2.Electrical Actuation
3.Mechanical Actuation
1.Manualy Actuation: - Manual linear actuators consist of hand-operated
components—such as gearboxes, guided linear motion mechanisms, knobs, and
hand wheels—which harness the manually generated power from the rotational
movement of screws and gears. Despite harnessing energy from rotation motion,
these actuating devices produce linear motion.
EX-Toggle switch & Push button.
2.Electrical Actuation: - Electric are actuators a combination of a servo motor with
worm gear to prevent reversal of drive direction by an unbalanced load. Electric
actuators are divided into two different types; rotary and linear.
EX-Limit switches.

3.Mechanical Actuation: - A mechanical actuator is a device designed to remotely

control or move a secondary mechanism via an external power source, which may
include include electric current and high-pressure oil or gas.
EX- Relay, Timer, Sensor, Contactor.

Toggle switch

 SPST: -A Single Pole Single Throw (SPST) switch is a switch that only has a
single input and can connect only to one output. This means it only has one
input terminal and only one output terminal. A Single Pole Single Throw
switch serves in circuits as on-off switches. When the switch is closed, the
circuit is on.
 SPDT: -A Single Pole Double Throw (SPDT) switch is a switch that only has a
single input and can connect to and switch between 2 outputs. This means it
has one input terminal and two output terminals. A Single Pole Double Throw
switch can serve a variety of functions in a circuit. It can serve as an on-off
switch, depending on how the circuit is wired.

 DPST: - A Double Pole Single Throw (DPST) switch is a switch that has 2 inputs
and 2 outputs; each input has 1 corresponding output. Each of the terminals
of a double pole single switch can either be in the on position (closed) or in
the off position (open).

 DPDT: - A Double Pole Double Throw (DPDT) switch is a switch that has 2
inputs and 4 outputs; each input has 2 corresponding outputs that it can
connect to. Each of the terminals of a double pole double switch can either be
in 1 of 2 positions. This makes the the double pole double throw switch a very
versatile switch.
SPCO: - Single Pole Change over Switch (On/On) Single Pole On/On Switch. Use this
to switch power from one device to another or for operating items such as 2 aspect
colour light signals.

QPDT: -Double Pole Double Throw (DPDT) - This type of relay has two rows of
change-over terminals. It is equivalent to two SPDT relays actuated by a single coil.
Including the two for the coil, this type of relay has eight terminals. Quadruple Pole
Double Throw (QTDP) - These relays can also be referred to as Quad Pole Double
Throw or 4PDT.
Push button
Type of push button: -
1. Type of push button (Depending upon contact)
2. Type of push button (Depending upon construction)
3. Type of push button (Depending upon operation)
4. Type of push button (Depending upon operation as per color code)
1. Depending upon contact: -
a.NO contact type
b.NC contact type
2. Depending upon construction: -
a. plain headed type

b. mushroom headed type

3. Depending upon operation:

a. start process

b. stop process
 4. Depending upon operation as per color code: -
a. green-start process

b. yellow-inch process

c. red-stop process

Advantages of PLC

1. Reduced space: PLCs are completely solid-state devices and hence are extremely
compact in comparison to hard-wired controller where electro-mechanical devices
are used.
2. Higher Life and Reliability: These devices are extremely rugged. The chances of
defect/damage are very less as there is very lesser moving mechanisms here.
1. Economical: As the defect probability is very less, one can consider it as one-time
investment. In this way, PLCs are undoubtedly most economical systems. Cost of PLC
recovers within a short period.
1. Energy saving: Average power consumption is just 1/10th of power consumed by an
equivalent relay-based control.
5.Ease of maintenance:
 Modular replacement
 Easy trouble shooting
 Error diagnostics with programming unit.
1. Tremendous flexibility: There is no requirement of rewiring if any change is required
to be implemented. It can carry out complex functions like arithmetic operations,
 counting, comparing, generation of time delay etc. It has a very high processing
speed and greater flexibility in both analog and digital process. “On Line”/ ‘Off Line’
programming is also possible in it.
1. Shorter Project Time: The hard-wired control system can be constructed only when
the task is fully defined. However, in case of PLC, the construction of the controller
and wiring are independent of control program definition.
1. Easier Storage Archiving and Documentation: This is due to its compatibility with PC-
AT, Printer and Floppy disk.

Disadvantage of PLC

1. There's too much work required in connecting wires.

2. There's difficulty with changes or replacements.
3. It's always difficult to find errors; And require skilful work force.
4. When a problem occurs, hold-up time is indefinite, usually long.
 SOFTWARE IMPLEMENTATION

OBJECTIVE :- Plc is controlling motor forward reverse process such

that if forward push button is pressed it run forward direction and
reverse pushbutton is pressed it run reverse direction . but if any
process is running its doesn’t run another process if stop push button
is used.
Ladder Logic Diagram (LAD)
ALGORITHAM

Pb1 i0.0 is running for forward process. if it’s on motor forward connection gets on
and its get on supply for q0.0.
If is on its can’t run the reverse direction process.
We have to use common stop push button connection i0.1
Same thing is possible for reverse direction its get on the contactor through motor
reverse supply connection q0.1 by pressing pb2 i0.1
If stop push button is pressed, then only we can active forward proses
Because we active interlock process here.
 CONCLUSION

 I have achieved my project that is motor forward reverse process using plc.
 process using S7 300 PLC.

 This was successfully implemented.

 I consider this project as a journey where I acquired knowledge automation

industry.

 Also gained some insights into the subject which I have

shared in this report.

1. Automation and Precision:

o PLCs enable precise control over the motor's direction, ensuring that forward
and reverse operations are executed accurately based on predefined
conditions and inputs.
2. Safety and Interlocking:
o The logic in the PLC ensures that both forward and reverse relays cannot be
activated simultaneously, which prevents short circuits and potential damage
to the motor and control system.
o Safety interlocks, such as limit switches, ensure the motor stops when it
reaches its physical limits, protecting both the motor and the mechanical
system it drives.
3. Scalability and Flexibility:
o PLCs are highly adaptable and can be easily reprogrammed to accommodate
changes in process requirements or system upgrades.
o Additional functionality, such as speed control, timing sequences, and
integration with other automation systems, can be added as needed.
4. Ease of Troubleshooting:
o PLCs provide diagnostic capabilities, making it easier to identify and
troubleshoot issues in the control logic or hardware.
o Status indicators and monitoring tools help maintenance personnel quickly
pinpoint problems and take corrective actions.
5. Cost-Effectiveness:
o While the initial setup cost of a PLC system might be higher than traditional
relay-based systems, the long-term benefits in terms of reliability, reduced
downtime, and maintenance costs make it a cost-effective solution.
6. Enhanced Control and Monitoring:
o PLCs offer advanced control features, such as real-time monitoring and data
logging, which enhance overall system performance and provide valuable
insights for optimizing operations.
7. Integration with Other Systems:
o PLCs can communicate with other automation systems, human-machine
interfaces (HMIs), and supervisory control and data acquisition (SCADA)
systems, providing a comprehensive control solution.