Documente Academic
Documente Profesional
Documente Cultură
On
By
Prof. R. G. Jamkar
CERTIFICATE
completed the project work for VIIIth semester during academic year 2014-2015.
ABSTRACT
ACKNOWLEDGEMENT
Firstly we would like to thanks our sir for his invaluable Guidance in our
topic. He took interest in checking all minute bugs in our project report and guided us
throughout the project duration.
Our deepest and most sincere feeling of gratitude to our H.O.D Dr. V. G.
Asutkar, who has kindly allowed us to work on this topic and for his valuable guideline
to us. We are also thankful to Prof. R. G. Jamkar for his valuable suggestion.
We also want to thank our classmates for their motivation. Finally we would
like to express our cordially thanks to all of those who helped us directly or indirectly
in this project work. We dedicated our project to the institution of our life that is our
parents.
INDEX
Sr. No. TOPIC Page No.
1. Introduction 07
1.1 Introduction
2. PLC 13
2.1 Introduction
2.2What is a PLC?
2.3 Central Processing Unit
2.4 Input/output interface system
2.5 PLC specification
4. SCADA 21
4.1 Introduction
4.2 Project Development Steps
6. Components of System 26
6.1 List of Components
1) IR Sensor
2) DC Motor
3) Solenoid Valve
4) Dryer
5) Conveyor
6) Small Car
7) Relay
8) Transformer
9) Block Diagram
10) Input interfacing Diagram
7. Working of System 38
7.1 Entry -Car Detection
7.2 Foam Wash
7.3 Brushing
7.4 Clean Wash
7.5 Drying
7.6 Exit
8. Ladder Diagram 39
10.Documentation 47
10.1 Digital Input-Output Datasheet
10.2 Advantages
10.3 Cost Analysis
10.4 Result
Chapter 1
System
1.1 Introduction:
The first automatic car washes appeared in the late 1930s. Automatic car washes
consist of tunnel-like buildings into which customers (or attendants) drive. Some car
washes have their customers pay through a computerized POS (point of sale unit), also
known as an "automatic cashier". The mechanism inputs the wash PLU into a master
computer or a tunnel controller automatically. When the sale is automated, after paying
the car is put into a line-up often called the stack or queue. The stack moves sequentially,
so the wash knows what each car purchased. After pulling up to the tunnel entrance, an
attendant usually guides the customer onto the track or conveyor. At some washes, both
tires will pass over a tire sensor, and the system will send several rollers. The tire sensor
lets the wash know where the wheels are and how far apart they are. On other systems
the employee may guide the customer on and hit a 'Send Car' button on the tunnel
controller, to manually send the rollers which push the car through. When the customer
is on the conveyor, the attendant will instruct the customer to put the vehicle into
neutral, release all brakes, and refrain from steering. Failure to do so can cause an
accident on the conveyor. The rollers come up behind the tires, pushing the car through
a detector, which measures vehicle length, allowing the controller to tailor the wash to
each individual vehicle. The equipment frame, or arches, vary in number and type. A
good car wash makes use of many different pieces of equipment and stages of chemical
application to thoroughly clean the vehicle.
Also visible is the conveyor. The carwash will generally start cleaning with pre-
soaks applied through special arches. They may apply a lower pH (mild acid) followed
by a higher pH (mild alkali), or the order may be reversed depending on chemical
suppliers and formula used. Chemical formulas and concentrations will also vary based
upon seasonal dirt and film on vehicles, as well
as exterior temperature, and other factors. Chemical dilution and application works in
combination with removal systems based on either high pressure water, friction, or a
combination of both. Chemical substances, while they are industrial strength, are not
used in harmful concentrations since car washes are designed not to harm a vehicle's
components or finish. The customer next encounters tire and wheel nozzles, which the
industry calls CTAs (Chemical Tire Applicators). These will apply specialized
formulations, which remove brake dust and build up from the surface of the wheels and
tires. The next arch will often be wraparounds, usually made of a soft cloth, or closed
cell foam material. These wraparounds should rub the front bumper and, after washing
the sides, will follow across the rear of the vehicle cleaning the rear including the license
plate area. Past the first wraps or entrance wraps may be a tire brush that will scrub the
tires and wheels. This low piece is often located beneath a mitter (the hanging ribbon-
like curtains of cloth that move front to back or side to side) or top wheels. There may
also be rocker panel washers which are shorter in size (ranging in size from 18 inches
[45 cm] up to 63 inches [160 cm] tall) that clean the lower parts of the vehicle. Most
rocker brushes house the motor below the brush hub so they don't inhibit cloth
movement and allow the brush to be mounted under a support frame or below a mitter.
Some car washes have multiple mitters, or a combination of mitters and top brushes.
After the mutter or top brushes the car may pass through a second set of
wraparounds. This may also be where high pressure water streams are used to clean
difficult to reach parts of the vehicle. The car generally passes over an under carriage
wash and/or has high pressure nozzles pointed at it from various positions. Next may
be a tire spinner, high pressure nozzles angled specifically to clean wheels and tires.
After the several wash stations the vehicle may go through triple foamers, usually red,
blue, and yellow, although colors can be customized with higher end chemical suppliers.
The triple foam process includes special cleaners as well as some protective paint
sealant. Protectants vary by manufacturer. Near the rinse is where a tire shining machine
is often installed, which is designed to apply silicone tire dressing to the tires. This
application makes the tires look good (new, and glossy) and preserves the rubber. Next
the vehicle is treated with a drying agent and a final rinse. Many carwashes utilize a
"spot free" rinse of soft water that has been filtered of chlorine and sent through semi
permeable membranes to produce highly purified water that will not leave spots. After
using spot free water, the vehicle is finished with forced air drying, in some cases
utilizing heat to produce a very dry car.
Typical "tunnel" car wash view from the inside
Older automatic washes-a majority of which were built prior to 1980-used to use
brushes with soft nylon bristles, which tended to leave a nylon deposit in the shape of a
bristle, called brush marks, on the vehicle's paint. Many brushes in the US are now
either cloth (which is not harmful to a car's finish, as long as it is flushed with plenty of
water to remove the grit from previous washes), or a closed cell foam brush, which does
not hold dirt or water, thus is far less likely to harm any painted finish, and can, in fact,
provide a gentle polishing effect to leave the paint much shinier. In order to avoid paint
marking issues, "touch less" or "no-touch" car washes were developed. This means the
car is washed with high water pressure instead of brushes. There is no contact with
friction so the chance of any damage is less, however the actual cleaning, or removal of
film from the paint, is nearly impossible with no touch systems. At "full-service" car
washes, the exterior of the car is washed mechanically with conveyor equipment, or in
some cases by hand, with attendants available to dry the car manually, and to clean the
interior (normally consisting of cleaning the windows, wiping the front and side dashes,
and vacuuming the carpet and upholstery). Many full service car washes also provide
"detailing" services, which may include polishing and waxing the car's exterior by hand
or machine, shampooing and steaming interiors, and other services to provide thorough
cleaning and protection to the car.
I. Pre-wash/foam wash:
V. Clean wash
Chapter 2
PLC
2.1 Introduction:
A PLC (Programmable Logic Controller) is usually called as Programmable
controller. It is a solid-state, digital, Industrial Computer. Upon first look, a PLC may
seem to be no more than a black box with wires bringing signals in and other wires
sending signals out. It might also appear there is some magic being done inside that
somehow decides when field devices should be turned on. In actuality, there is no
magic. The PLC is a computer, and someone had to tell it what to do. The PLC knows
what to do through a program that was developed and then entered into its memory. The
PLC is a computer, however without a set of instructions telling it what to do, it is
nothing more than a full of electronic components. Without instructions, the black box
that we call a PLC can do nothing. The user program is the list of instructions that tells
the PLC what to do.
Computers such as PLC can be wonderful tools, however it might appear. They
only do exactly what the human programmer told them to do.
The central processing unit (CPU) is the heart of PLC. The CPU reads signals
and follows the instructions that a programmer has stored in memory. As a result of
solved program, the PLC turns outputs or field controlled devices turn on-off.
The CPU consists of following three parts:
• Processor
• Memory System
• Power Supply
Input section: The input sec0tion of PLC contains two major areas. First the
physical screw terminals where incoming signals from field input devices. The
second section is PLC internal conversion electronics. The function of the
input section electronic component is to convert and isolate the high voltage
input levels from the field devices.
supervises the entire process. The CPU solves the user program and updates
the status of the output.
Output section :The result of looking at or reading the ON/OFF status of the
inputs and using the information to solve the user ladder program is to send,
updated signals to the output section is simply a series of switches, one of each
output point, that are controlled by CPU and are used to turn output devices
ON/OFF.
Field hardware devices: They will stop the conveyor motor by de-energizing
the motor starter coil, when the products are sensed. The motor starter is a
device control by PLC. The devices that are controlled by PLC output section
screw terminals are the field hardware devices.
Chapter 3
TYPES OF DCS:
1) Conventional DCS.
2) PLC based DCS.
3) Hybrid DCS.
4) Open DCS System
CONVENTIONAL DCS
This is a pure “Process only” control system. Usually purchased from one vendor.
This DCS arranged into three categories:
• Small - Less than $ 100,000.
• Medium - Greater than $100,000 & Less than $500,000.
• Large - Greater than $500,000.
PLC Based DCS: - This is a network of PLC’s used to perform the task of
conventional DCS and programmable functionality when required.
Languages Supported:-
Ladder Diagram
Functional Block Diagram
Sequential Function Chart
Structured Text
Different Controllers:-
Chapter 4
SCADA
4.1 Introduction:
A SCADA system may be regarded as an extension of computer data
logger systems. SCADA system is one of the plant automation process due to its visual
representation and its advance features. As its name suggests that this system not only
a data acquisition but also it gives master supervisory control and able to take decision
regarding the project.
SCADA system is very popular because it gives total plant appearance on a
single screen and its monitoring and control for the user. It made very easy to look into
the plant and study the different controlling parameters with different device making
with their changes continuously. So it gives the interesting and visual plant process
appearance without going into the actual field. In practice, the different SCADA
software are available in market. Everyone is having its different features but the basic
concept is same for all. RS VIEW-works-Rockwell Software: RS VIEW-works is very
popular SCADA software.
The project can be studied using this SCADA alone i.e. without link with PLC,
by using Visual basic languages with by linking with PLC. It gives control over total
PLC program. SCADA is having its own graphic display on which the mimics are
developed. Different mimics can be made as desired or the different structures can be
easily brought from the library of RS view works software itself. After constructing the
total process mimic then we have to assign the tag database for i.e. button, tank, control
valve, light, motor etc.
4. System Configuration:
Channel-:
In this, the proper RS232, DF 485 etc. should be select for
channelling between PLC & SCADA. e.g. AB-DFI-1 (Allen-
Bradley)
Node:
Node is to be assign of PLC i.e. for Allen-Bradley
Micrologix/SLC I-DH-485.(communication)
Station link gateway:
AB-DFI-1
OK
Accept
Scan class:
Generally this is kept as default setting.
Tag data base
It creates and edit tag data base. Tag data base consists of records
called Tags. Tags are organizing tags in to group using folders.
Three types of tags can creates.
Chapter 5
Stages of Car Washing System
1. Entry :-
3. Brushing :-
5. Drying Section :-
6. Exit :-
Chapter 6
Components of Car Washing System
6.1 DC Motor
Specifications of DC Motors:-
We are using DC Motors for two main purpose.
Rotation of Conveyor
-Supply Voltage : 24V
-RPM : 30 rpm
Wheel Brushes
-Supply Voltage : 24V
-RPM : 200 rpm
Operating Voltage:- 24 V DC
Simple ON-OFF
2 Way Valve
Principle:
potentiometer is tuned inside room/building for maximum sensitivity and then taken
out in open sunlight, it will require retuning, since sun’s rays also contain Infrared (IR)
frequencies, thus acting as a IR source (transmitter). This will disturb the receiver’s
sensing capacity. Hence it needs to be returned to work perfectly in the new
surroundings. The output of IR receiver goes low when it receives IR signal. Hence
the output pin is normally low because, though the IR LED is continuously
transmitting, due to no obstacle, nothing is reflected back to the IR receiver. The
indication LED is off. When an obstacle is encountered, the output of IR receiver goes
low, IR signal is reflected from the obstacle surface. This drives the output of the
comparator low. This output is connected to the cathode of the LED, which then turns
ON.
6.4 Dryer
Fig: Dryer
6.5 Conveyor:-
A conveyor system is an common piece of mechanical handling equipment
That moves materials from one location to another. Conveyors are especially useful in
applications involving the transportation of heavy or bulky materials.
Conveyor systems allow quick and efficient transportation for a wide variety of
materials.
Specifications:-
1. Step-up transformer:
In this transformer, the voltage generated at the secondary is higher than the
voltage applied at its primary.
2. Step-down transformer:
In this, the voltage generated at the secondary is lower than the voltage applied
at its primary.
Here, we have used a step down transformer to generate 12 volt ac supply from 220
volt ac supply.
Specifications:
Input AC Voltage : 220 V
Output AC Voltage: 12 V
Input current : 10 -20 A
Output Current : 1A & 0.5 A
Figure:- Transformer
6.7 Relay
A relay is an electrically operated switch. Many relays use
an electromagnet to mechanically operate a switch, but other operating principles are
also used, such as solid-state relays. Relays are used where it is necessary to control a
circuit by a low-power signal (with complete electrical isolation between control and
controlled circuits), or where several circuits must be controlled by one signal. The
first relays were used in long distance telegraph circuits as amplifiers: they repeated
the signal coming in from one circuit and re-transmitted it on another circuit. Relays
were used extensively in telephone exchanges and early computers to perform logical
operations.
6.8 Car:-
DESCRIPTION:
The figure shows the block diagram of Automatic Car Washing
System. A 230V AC Supply is given as input to the SMPS for obtaining 24V DC, since
PLC can operate at 24V DC. Terminal Block is used for multi inputs and outputs.
PLC is connected to PC through RS-232 communication cable for
downloading or uploading the program. Conveyor is used for shifting the car through
various stages of washing. We use 100 rpm DC motors for driving the conveyor belt
via pulley and for driving brushes When conveyor`s components are in good condition
and well aligned, it will operate properly. Proper clamping of car wheels on the
conveyor is needed in order to avoid displacement. Generally brushes are now either
cloth (which is not harmful to a cars finish, as long as it is flushed with plenty of water
to remove the grit from previous washes), or a brush, which does not hold dirt or water.
Thus it does not harm any painted finish. It provides a gentle polishing effect to leave
the paint much shinier. High pressure nozzles are pointed at various position for
spraying soap solution and water to clean difficult to reach parts of the vehicle. At the
end, hot steam air is generally used for drying the car. Construction of this system is
depends upon the requirement. A visual programming language known as the Ladder
Logic was used to program the PLC. An Infrared sensor is used which emits radiation
in order to sense presence of car at the entry level. Once the Infrared radiation is cut by
the car an input signal is given to PLC. Switches are present in the HMI screen. As an
input signal is received, PLC starts executing the Ladder Program.
First the conveyor moves by fixing a timer for few sec. After that,
it stops at the stage of washing. In general process, Car is cleaned by spraying soap
solutions, rinsing, brushing, drying, waxing, etc. depends on the requirement of
customer. We have chosen spraying water, Brushing and finally drying for cleaning the
car.
Each activity is carried out for a certain time period. Water is
sprayed for few sec and nozzle is closed. Then four brushes rotate for few sec and stops.
Now the conveyor starts moving to next stage. After few sec, it stops for drying. Two
fans are used for drying the car up to few sec. Then the conveyor carrying car moves to
the exit level. Again an IR sensor senses the car and sends an input signal to
Programmable logic controller.
Timings are set by using timers in ladder programming. These timings can be varied
depending upon the requirement.
6.11 Output interfacing circuit diagram of DC Motor, Solenoid & Dryer with
Hybrid DCS:-
Chapter 7
Working of System
Input-IR sensor:
When car comes on IR-sensor, sensor sense and conveyor starts moving
with the help of motor (M2) until it will reach to the next IR sensor
section
As car reached to next ir section then entry gate start to open for 2sec
Pre-Wash Section
As the car reaches in pre-wash chamber, shampoo water falls on the car
by opening valve (V1).
Valve will remain on for 5 sec. After 5sec. valve will close
automatically.
Again conveyor starts moving until it will reach to the next ir sensor
section(Brushing section)
Brushing Section
As the conveyor stops vertical brushes starts brushing the car for
10sec. and stop.
Again conveyor starts moving until it will reach to the next ir sensor
section(Clean wash section)
Exit
After drying stage completion open exit gate with the help of motor
(M6) for 2 sec. and stop.
Again conveyor starts starts moving until it will reach to the next ir
sensor section.
Close the gate (M6)
Chapter 8
Ladder Diagram for project:
Chapter 9
The SCADA for our project is shown below. It contains the conveyor belt,
control valve, IR sensor, Tanks, Dryer and electric motors with the different washing
sections namely prewashing, brushing, wheel brushing, washing and drying.
SCADA Mimic:-
Chapter 10
Documentation
Advantages
Less Area
Less amount of water is required
Time requirement is less
Pollution free
Man power requirement is less
Cost Analysis:
Total cost required for the implementation of PLC Based Automatic Car Wash System
is
Rs. 6000/-
Result:-
In Automatic Car Washing System, we performed all the operations needed
to clean the car successfully by using PLC and hybrid compact logix L43 DCS, also
developed mimic of the whole system on SCADA RS VIEW 32 Works and checked
the overall process step by step by visualization.
Chapter 11
Conclusion:-
This prototype will help to perform car washing automatically results
in high quality end product. Thus it will be User-friendly and capable to wash multiple
cars at a time. Also require less man power, time and no pollution.
References:-
1 .www.philips.com
2. www.ieee.com
3. www.kkeindia.com
4. www.rockwellautomation.com
5. www.indiamart.com/3-brush-automatic-car-wash-system.html
6.www.youtube.com/automatic-car-wash