SMART ELECTRIC CONTROL SYSTEM USING PLC & HMI

Transcription

1 International Journal of Mechanical Engineering and Technology (IJMET) Volume 9, Issue 4, April 2018, pp , Article ID: IJMET_09_04_062 Available online at ISSN Print: and ISSN Online: IAEME Publication Scopus Indexed SMART ELECTRIC CONTROL SYSTEM USING PLC & HMI Mahesh Kumar Gupta, Prince Kumar Gupta, Rajat Kumar Giri and Abhishek Gupta Department of Mechanical Engineering, SRM Institute of Science and Technology, NCR Campus, Ghaziabad, India ABSTRACT Smart Electric Control System is an intelligent system which aims to manage all the electrical system using automation technology. There is an increasing demand in building for smart electric control system, where appliances can be controlled through switches and the HMI (Human Machine Interface) both. It is employed to maximize the energy saving of the lighting system and satisfy the building codes. It serves to provide the right amount of electric where and when it is needed. It complies with the green building and energy conservation programs. It is designed using the complete automation technology which includes PLC (Programmable Logic Controller) and HMI interface and its screen design, input and output power wiring as well as control wiring. The panel wiring is done in the Automation Studio software. There is an emergency power cut switch available on its screen which is actually not physically present on the control panel. Each component serves a purpose in this system. Relays are used to control the output mode of operation. SMPS (Switch Mode Power Supply) works as a rectifier which used to convert AC current to DC current. Key words: Automation Studio, HMI, PLC, Relays, SMPS, DOP Soft, WPL Soft Cite this Article: Mahesh Kumar Gupta, Prince Kumar Gupta, Rajat Kumar Giri and Abhishek Gupta, Smart Electric Control System using PLC & HMI, International Journal of Mechanical Engineering and Technology 9(4), 2018, pp INTRODUCTION This research paper is developed with only aim to control the electrical components (e.g., a college) more smartly using the Automation technology. In a college all the electrical components are being controlled by the switches only. This research paper includes the modernization of this conventional system by designing a control panel that contains command parts like relays and PLC to run the programs that is designed to control and monitor the system. HMI is used to control and monitor which helps to assure the balanced control system. The main aim of upgrading the system is to overcome the problem of wastage of electricity. The implementation of this project allows hassle-free operation and efficient control system editor@iaeme.com

2 Smart Electric Control System using PLC & HMI 2. PROBLEM FORMULATION As India is looming under the problem of electricity shortage and there is need to save the electricity for our future generation, as the flow of electricity is unidirectional in nature and it s not a cyclic process. So an effort needs to be made to minimize the wastage of electricity by the smart control of the electrical components. Since it often happens, students and faculties forget to turn off the electrical components before leaving their classrooms or their office and security staffs need to check all the classrooms and offices one by one whether all the electrical components are switched off or not. It takes a lot more time and staffs to check the status of all electrical components. 3. PROBLEM SOLUTION The above problem statement can be minimized by designing a control panel that contains relays, SMPS, PLC and HMI which provide the easy access and control of system. WPL Soft 2.41 is used to program the PLC in Ladder logic programming language and DOP Soft is used to design the screen of the HMI which provides the easy control access. Relays are used for latching and interlocking and to protect the outputs. The Source type input wiring and Sink type of output wiring is carried out in PLC input/output ports. In the source type of wiring 24V is supplied common and 0V is supplied to the input components whereas in sink type of wiring 0V is supplied to common and 24V is supplied to the outputs. The sink type of wiring is mostly preferred in case of output wiring so that the outputs can be protected. The use of this technology results to reduce the wastage of electricity and fatal accidents. 4. METHODOLOGY ADOPTED Start Problem Formulation Problem Solution Hardwiring and Interfacing PLC and HMI Programming Configuration and Communication NO Testing YES End editor@iaeme.com

3 Mahesh Kumar Gupta, Prince Kumar Gupta, Rajat Kumar Giri and Abhishek Gupta PLC HMI Hardware Relays Projects Modules Output Devices Switches WPL soft Software DOP soft Automation Studio 5. HARDWIRING AND INTERFACING Power wiring shows the kind of power supply to the inputs, outputs, PLC and HMI whereas the control wiring shows the control terminal connections of the outputs and inputs so they can perform their functions properly without any problem. Power and Control Wiring

4 Smart Electric Control System using PLC & HMI Figure 1 Physical Model of Control Panel used for testing 6. HMI & PLC PROGRAMMING 6.1. PLC (CPU) Scanning Process A PLC is an industrial grade computer that is capable of being programmed to perform control functions. A PLC consists of two basic sections i.e., the CPU (Central Processing Unit) and the input/output interface system. During its operation, the CPU completes three processes: Step 1: It reads the input data from the field devices via input interface. Step 2: It executes or performs the control program stored in the memory system. Step 3: It writes the output devices via the output interface. These processes are known as Scanning. A personal computer is the most commonly used programming device. In this research paper, Delta DVP 14SS2 model is used for programming using ladder logic programming language and the program has uploaded into a PLC processor via serial data communication link editor@iaeme.com

5 Mahesh Kumar Gupta, Prince Kumar Gupta, Rajat Kumar Giri and Abhishek Gupta Delta PLC Ladder Logic Program In this program, the outputs Y0 & Y1 represents Light and Fan in Room Number 01 and X0 & X1 are the maintained switches whereas M2 & M3 are the touch switches designed in the HMI for these outputs. The outputs Y2 & Y3 represents Light and Fan in Room Number 02 and X2 & X3 are the maintained switches whereas M4 & M5 are the touch switches designed in the HMI for these outputs. The outputs Y4 & Y5 are the indicators placed in the HMI as well as in the control panel which will indicate the status of any output in Room number 01 and 02. The touch emergency switch is placed in the HMI that will turn OFF the power in one click HMI Screen Design Programming of the HMI involves assigning tags to screen elements. A tag is basically a link or connection between a screen element of the HMI and an address in the PLC. In this project, the DOP Soft is used to design the screen of the HMI that provides easy access and control of system editor@iaeme.com

6 Smart Electric Control System using PLC & HMI Figure 2 Home Screen of HMI Screen The HMI screen is password protected which means only authorized person can access the HMI screen. Figure 3 Password Protected Screen of HMI Once the correct password is entered into the HMI screen, the user can access the electrical controls of individual rooms and offices. The multiple control room screen helps the user to control and monitor the status of all electrical components placed in those rooms or offices. The MAIN ON/OFF Switch is the emergency stop switch that is placed in the HMI but it s not available on the main control panel editor@iaeme.com

7 Mahesh Kumar Gupta, Prince Kumar Gupta, Rajat Kumar Giri and Abhishek Gupta Figure 4 Multiple Control Room Screen of HMI If anything is ON in any of these two rooms then the indicator termed as HI! Will blink otherwise it will not blink. The user can also control the outputs of these two rooms by clicking on the touch screen of the HMI. ROOM 01 & ROOM 02 showing on these screen are the actually touch switches that will allow the user to gain the access of these rooms. Figure 5 Room No 01 Output control and Status Figure 6 Room No 02 Output control and Status editor@iaeme.com

8 Smart Electric Control System using PLC & HMI 7. RESULTS After the configuration and communication of the PLC, HMI, Inputs and Outputs, the project is tested on the control panel and found the successful control of all electrical components through maintained switches as well as through the HMI screen touch buttons. 8. CONCLUSIONS This work is carried out to design a Smart Electric Control System using PLC and HMI. The modernization of the electrical control system can be effectively achieved by designing a control panel having the automation equipment like PLC, HMI and Relays. This control panel can provide the easy access of electrical equipment to the user and can also save time. This project can help to minimize the wastage of electricity, save time and reduces the complex conventional wiring system. REFERENCES [1] Dr. A. Selwin Mich Priyadharson and Prabhu Kumar Surarapu, PLC-HMI Based Automatic Screen Printing System International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 10, October 2017, pp , Article ID: IJMET_08_10_013. [2] Amanpreet Kaur and Er. Pradeep Singh, Paper Machine Automation Using PLC, VFD s and HMI International Journal of Engineering Research & Technology (IJERT) Vol 8, Issue 05, May 2017, ISSN: [3] [4] Programmable Logic Controllers by Frank D. Petruzella. [5] Programmable Logic Controllers by W. Bolton. [6] Erwin Normanyo, Francis Husinu, Ofosu Robert Agyare Developing a Human Machine Interface (HMI) for Industrial Automated Systems using Siemens Simatic WinCC Flexible Advanced Software Journal of Emerging Trends in Computing and Information Sciences Vol. 5, No. 2 February 2014, ISSN [7] editor@iaeme.com