World Applied Sciences Journal 16 (1): 34-38, 2012 ISSN 1818-4952 IDOSI Publications, 2012

Design and Analysis of a Remote Sensing Car Speed on a Runway Based Programmable Logic Controller
Yousif I. Al-Mashhadany and Huthaifa Humady Jasem Department of Electrical Engineering, College of Engineering, University of Anbar, Baghdad, Iraq
Abstract: Programmable logic control (PLC) has many definitions according to application or function. It is a device that has the ability to program and execute many processes at the same time and it has a wide range of applications in many scientific fields. This paper presents the design and analysis for a car speed measurement on a run away by using remote sensing sensor. This technique is implemented using ultra sonic sensors. This design can be described by three main parts: theory of PLC and measurement methods, the software design of PLC and method calculation for car speed measurement. Finally, after many runs, the accuracy of the measurement is increased. Satisfying results are obtained. That explains the ability to depend on this design in practice implementation as fully remote sensing car speed measurements. Key words: Central Processing Unit % Remote sensing % Ladder Diagram INTRODUCTION PLC, as it is universally called, is the 'work horse' of industrial automation. Sometimes it is also called the 'Cinderella of Control', because it is not well treated in colleges and universities, but when control engineers use PLCs in industry they wonder how they lived without them. We think that there are a lot of three term controllers in the world, but there are many more PLCs! PLC is important because all production processes go through a fixed repetitive sequence of operations that involve logical steps and decisions. A PLC is used to control, time and regulate the sequence. Examples of production processes that are controlled using PLCs are metal machining sequences, product assembly lines and batch chemical processes. Logical control has been used to control sequences of actions in automatic manufacturing systems for many years. Originally, a logical control system was 'hard wired' using electronic relays, timers and logical units. These systems were inflexible. Once a 'hard wired' logic system had been constructed, then if the machining schedule was altered for another type of product, the logic control system had to be manually rewired for the new application. This was inflexible and time consuming. It restricted the production scheduling of a factory and made changing products difficult [1]. This situation began to change in the 1970's when mini-computers became available. It is easy to perform switching, time delays and logic in computer programmers. A computer programmer is also easy to change when the control problem changes and allows many more logical functions than are possible with hardwired logic control. When reliable microprocessors became available in the 1980's, with cheap memory and flexible input-output features, then the modern generation of PLCs began to emerge. Today the microcomputer based PLC is a robust, reliable instrument with many functions and features. Even cheap PLC's are able to control a medium scale automatic machining station or chemical batch reactor. Large PLC systems are capable of running an entire factory automation system [2]. A PLC is a specialized computer used to control machines and processes. It therefore shares common terms with typical PCs like central processing unit, memory, software and communications. Unlike a personal computer though the PLC is designed to survive in a rugged industrial atmosphere and to be very flexible in how it interfaces with inputs and outputs to the real world. The components that make a PLC work can be divided into three core areas (Figure 1 ).

Corresponding Auhthor: Dr. Yousif I. Al-Mashhadany, Department of Electrical Engineering, College of Engineering, University of Anbar, Baghdad, Iraq. Tel: +9647811856435.

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World Appl. Sci. J., 16 (1): 34-38, 2012

(voltage, current, temperature). Examples of this type are CP1H Omron, Siemens S7-200 and Fuji Electric SPB. Medium PLC: it is a PLC which has CPU module, I / O or communication port which are separate. Each module is connected by a connector or backplane. It has a capacity of more than 2000 I / O. Examples of this type are Omron CS1, Siemens S7-300. Large PLC: This kind of PLC is nearly equal to the medium one but it has large I/O capacity and more able to be connected with the higher control systems. Examples of this type are CVM1 Omron, Siemens S7-400. Based on the type of input PLC / output PLC can be divided into: Fig. 1: PLC [MTA 382] [3]. C C C The power supply and rack. The central processing unit (CPU) The input/output (I/O) section. Discrete I / O: It is a logic shaped digital input and output as high level with 24VDC, or low level with 0V or as a relay contact output that can be irrigated up to 240VAC. Special I / O: it is a I / O that has special functions such as: C C C C C C C Analog Input Modules Modules temperature PT100 module or thermocouple (low-level analog inputs) High Speed Counter Module which is a frequency logic with generally high level 5V, 12V or 24V. Fuzzy Logic Module PID Module Servo Module Communication protocol module form made by each manufacturer, for example, Field bus, Mod bus, Profile bus, Ethernet, Seismic way, Device Net, Control Net.

PLCs come in many shapes and sizes. They can be so small as to fit in your shirt pocket while more involved control systems require large PLC racks. Smaller PLCs (a.k.a. bricks) are typically designed with fixed I/O points. For our consideration, well look at the more modular rack based systems. Its called modular because the rack can accept many different types of I/O modules that simply slide into the rack and plug in. The brain of the whole PLC is the CPU module. This module typically lives in the slot beside the power supply. Manufacturers offer different types of CPUs based on the complexity needed for the system. The CPU consists of a microprocessor, memory chip and other integrated circuits to control logic, monitoring and communications. The CPU has different operating modes. In programming mode it accepts the downloaded logic from a PC. The CPU is then placed in run mode so that it can execute the program and operate the process. PLC has several types. Based on the size of the module type, PLC is divided into several types [4]: Micro PLC or Small PLC: It is the simplest PLC with a power supply module, CPU, I / O modules and communication ports in a single chassis. These PLC types are usually limited to a few discrete I / O and can be expanded. There are various micro PLCs on the market today. The vast majority offer analog I / O, with just about any micro PLC, or for that matter PLC in general. When the application requires the monitoring of various analog signals, a separate module is required for each signal 35

Softwae of Plc System: There are many types of software's that have ability to write the instructions to PLC as a program. The software depends upon the type of PLC used in the design. The types of software's with PLC can be as follows: C C C Sequential Function Chart (SFC). Instruction List (IL). Ladder Diagram (LD).

The use of LD in programming the ladder-logic approach is popular because of its perceived similarity to standard electrical circuits. Two vertical lines supplying the power are drawn at each of the sides of the diagram with the lines of logic drawn in horizontal lines (as shown in Figure 2).

World Appl. Sci. J., 16 (1): 34-38, 2012

Bar of instruction

Simulation instruction

Window of program design

Fig. 2: Main LD program and its simulation.

The Structure of LD Program describes the PLC program through Graphic code such as coil or contact which is used in Relay logic diagram. Figure 2 describes the comments for the relevant rung. Rung means the gathering of continued line connected longitudinally. That is, from the below Figure, row 1~4 makes one rung and row 5 makes one rung. From the above figure, {END} of row 6 indicates the end of main program. The error action processing connected to the next row is a type of subprogram and row 4 is calling this subroutine. It is available to use Toolbox by attaching it on the desired position by mouse. The following figure shows various tools and their names in the toolbox. In this design we'll be using from {FB} the blocks counter and timer TON and from {F} the blocks XOR and DIV. Steps Design for Car Speed Measurement: The design for car speed measurement based upon remote sensing sensors on a runway can be executed by using LD program with the following steps: C C C Design flasher using XOR and TON. The O/P of flasher is connected to the Counter. The flasher starts when the car passes across the first sensor and the counter will start counting and stops when the car passes across the second sensor. The DIV will divide the distance between the two sensors by the time between them to calculate the speed of the car. If the car crosses the way in opposite direction i.e. the first sensing is from the second sensor not the first sensor, the system design will execute the alarm indication.

Fig. 3: Description of using function block in LD program.

Figure 4 presents the program in LD software for all the design steps explained above. Simulation Results: The simulation for the design is achieved by explaining the work for each block in the design using the simulator button in the LD program. The PLC used in the design is GM7 GLOFE. The input to system design will be made manually instead of the sensing of remote sensor (electric-photo sensor) to check that the o/p of the design is the same as in practice implementation. The job for each block in the design diagram is shown in Figure 4. which can be explained as follows: The Flasher: The task of this block is to generate a series of pulses that has a constant width which can be detected by the value of preset time (pt) in TON block. These pulses are generated from restarting the TON 36

Fig. 4: Design for car speed measurement based upon remote sensing sensor.

World Appl. Sci. J., 16 (1): 34-38, 2012

Fig. 5: The flasher block.

were the last gives a logic 1 on its o/p Q after enabling it with a delay equal to a preset time value. O/p Q is connected to one of the i/ps of an XOR gate and the other I/p is connected to the sensor. The TON enabled form the o/p of the XOR gate, when sensor energized from a motion of target gives logic 1, the o/p of the XOR will be logic 1. The XOR gate will enable the TON which gives alogic1 after (pt) to the XOR which returns its o/p to logic 0, which in turn disables the TON. so XOR i/p's well IN1(Q)=0 and IN2(sensor)=1 which gives o/p=1 and hence TON is enabled. by repeating this process, a period of pulses is generated. [Figure (4)] this process will be stopped if the other sensor gives logic1 to the additional XOR which enables the XOR1. The Counter: The job of the counter is the computation of the time that the target requires to pass the distance between sensors; this is done by using a CTU block that counts the no. of pulses coming from the flasher which represents the time (Figure 6). The Divider: This block implements the speed rule (speed = distance/time), where it divides the distance between sensors at IN1 by the time from CTU at IN2 st which the speed is o/p (Figure 7). After the connection of the three main parts (flasher, counter and divider ) the design can be simulated as one block, its inputs are the two signals from the remote sensing and the output is the signal for display of car speed with a certain unit ( Km/ hour, Mile/hour and m/s ). Figure 8 presents the overall simulation of the system design. The number resulting from the divider which represents the speed is approximately the real speed it is caused from: the relatively small distance between sensors, the divider takes only the integer number and cancels after point and the fault from delay sensors energized. The probability of error well increase as the speed of the car rises, adding to that the system can only detect one target(car) were other target basing at the same time well caused error in the counting which mean error speed calculation. The two main problems above can be overcome by made normalization for high speed by adding to program IF- condition with limited speed to recorded any car that up-normal with limit rule for road and to made the normalization for divider to get high accuracy for calculation.

Fig. 6: The counter block.

Fig. 7: The divider block.

Fig. 8: Program and simulation of speed car measurement design. 37

World Appl. Sci. J., 16 (1): 34-38, 2012

The problem for passing more than one car cross the sensor can be overcome by hardware where we adding the third sensor and change the position of the first two sensors to middle the road instead of side it. After getting the signals from these sensors will calculate the speed of each car separatly. After made many experiments and compare between results this system, it can be seen that the results are very high accurate system and it has the ability to overcome many problems that realted to status of weather such as dust and high degree of temperature when we compare with other type of measurement of speed such as radar system and image processing system. CONCULSION From the system description of the design and the simulation results, many running, trial and error experiments were made. we can concluded that the design can be configured in many shapes by using different blocks and function blocks, we can even use different programs and also can modify the result more accurately in the same design with some changes in the hardware part or software (programming). In the hardware processing the distance between the two sensors can be increased and used high quality sensor (which has high speed request). In the software processing the preset time of the TON (on-delay timer) blocks can be changed (i.e. change from second to mille second ) to increase the accuracy of accounting and changing number of divisions (as numerator) which represents the distance between sensors and make it as large as possible by reducing its unit (i.e. change the unit from meter to millimeter). This process will round up the number to integer value and reduce the mantissa (the design is adaptive and can be calculate speed in Km/h or mile/h). All that changes can give the design accuracy and the ability to overcome errors and its results will be more acceptable to be implemented in practice.

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