UPGRADATION OF EMA-6 USING SIEMENS S7-200

S7-200 PLC PROGRAMMING:

STEP 7-MICRO/WIN is the programming language used for Programming of SIMATIC S7-200 PLC PLC STEP 7 consists of number of instructions that must be arranged in a logical order to obtain The desired PLC operation. These instructions are divided into 3 groups Standard instructions Special instructions High speed instructions

STANDARD INSTRUCTIONS:
Standard instructions consists of instructions that are found inmost programs.Standard Instructions inculde timer , counter , logical, increment/decrement move and block instructions.

SPECIAL INSTRUCTIONS:
Special instructions are used to manipulate data. It includes shift , table , find conversion , For/next and real time instructions.

HIGH SPEED INSTRUCTIONS:

High speed instructions allow for events and interrupts to occur independent of the PLC scan

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type .These include high speed counters , interrupt output and transmit instructions. The programming software can run off-line or on line . Off line programming allows the user to edit the ladder diagram and perform a number of maintenance tasks. The PLC does not need to be connected to the programming device in this mode. On-line programming requires the PLC to be connected to the programming device. In this mode program changes are downloaded to PLC. IN addition , status of the input and output elements can be monitored.

The CPU can be started stopped or reset. In order to understand the instruction the PLC is to carry out an understanding of the language is necessary. The language of PLC ladder logic consists of commonly used set os symbols that represent control component and instructions. With the STEP-7 three modes of representation can be used and these are: Ladder diagram(LAD) Functional block diagram(FBD) Statement list (STL)

LADDER DIAGRAM:
BIT

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The Ladder diagram method is graphical representation of control task using logic symbols. The symbols are arranged in horizontal rungs. Ladder structure is similar to switch analog of givemn problem. Hence we can directly reduce the ladder structure by replacing swithces with the contacts and output terminals with coils. Ladder diagram is simple , direct and easy to understand by anyone.

FUNCTIONAL BLOCK DIAGRAM: AND

OR

The FBD method is a graphical representation of the control task using logic symbols , which are used in digital circuits. The basic symbols used in FBD is the rectangular box, inputs are at the left LD and outputs are a

BIT

right of the function symbol.

A STATEMENT LIST: BIT O BIT

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LDN

UPGRADATION OF EMA-6 USING SIEMENS S7-200

The STL method uses mnemonic abbreviations to formulate control tasks.

STL is a high level structured language designed for expressing complex statements not easily handled in a graphical format. STL has a rich set of data types to accomodate analog and digital values, times, dates and other data suited automation projects. The program written in STL method is called as control statements Control statements is an instruction to the processor as to how it has to execute the program and what operation is to be carried out.

CONTACTS:

NORMALLY OPEN (NO) CLOSED(NC)

NORMALLY

One of the most confusing aspects of PLC programming for the first time

users is the relationship between the device that controls a status bit and the programming function that uses a status bit . Two of the most common programming function are the normally open (NO) contact and the normally closed (NC) contact.

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Symbolically , power flows through these contacts when they are closed. Normally open contact (NO) is true ( closed) when the input or output status bit controlling the contact is 1. The normally closed contact(NC) is true (closed) when the input or output status bit controlling the contact is 0.

COILS:

Coils represent relays that are energised when power floes to them. When a coil is energized, it causes a corresponding output to turn on by changing the state of the status bit controlling that output is 1.the same output status bit may be used to control normally open and normally closed contacts elsewhere in the program. Boxes represent various instructions or functions that are executed when power flows to the Box.

AND OPERATION:
Each network on the ladder represents a logic operation . The following programming example

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demonstrates an AND operation. Two contact closures and one output coil are placed on network 1.they were assigned addresses I0.0, I0.1 &Q0.0. Note that in the STL a new logic operation always begins with a load instruction (LD).In this example I0.0(i/p 1) and (A in the STL)I 0.1(i/p2) must be true in order for O/P Q0.0 (o/p1) to be true. It can also be seen that I0.0 and I0.1 must be true or Q0.0 to be true by looking at the function block diagram represenation. LAD REPRESENTATION FBD REPRESENTATION I0.0 I0.1 Q0.0 STL REPRESENTATION

LD A Q0.0

1 I0.0 I0.1

AND

I0.0

OR OPERATION:
In this example an OR opearation is used in network1. It can be seen that if either I/P I0.2 (I/P3) Or (0 in STL) I/P I0.3 (I/P4), or both are true , then uotput i0.1 (0/P) will be true. LAD FBD I0.2 LD I0.2 REP I0.2 STL REP

O R

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I0.3 I0.3 Q0.1

I0.3

PROGRAMMING NO & NC CONTACTS:

INPUT IMMEDIATE

The normally open immediate contact is closed (ON) when the bit value of the referenced physical input point n is equal to 1. In STL the normally open immediate contacts represented by the load immediate ,AND immediate, and OR immediate instructions. These point n to the top of the stack immediatley. The normally closed immediatate contact is closed (ON) when the bit value of referenced phsical input point n is equal to 0. In the STL , the normally closed immediate contact is represented by the load NOT immediate , AND NOT and OR NOT immediate instructions. Those instructions load AND or OR the Logical NOT immediate instructions . Those instructions load AND or OR the logical NOT of The value of the refrenced physical input point n to the top of the stack immediately.

PROGRAMMING TIMERS:
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S7-200 timers have he following characterstics: Timers are controlled with the signal enabling input, and have a current value that maintains the elapsed time since the timer was enabled . The timers also have a preset time value (PT) i.e. compared to the current value.Each time the current value is updated and when the timer instruction is executed. The timer bit is set or reset based upon the result of the comparision of current value 0 the preset time value. When the current value is greater that or equal to the present time value the timer bit(T-bit) is turned on.

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DESCRIPITION OF CPU MODULE:

The CPU controls and supervises all operations within the PLC, carrying out program instructions stored in the memory . An interanl communication highway , or bus system, Carries information to and from the CPU, memory and I/O units under control of the CPU . the CPU is supplied with aq clock frequency which detemines the operating speed of the PLC And provides titming for all the elements in the system.

The s7-200 CPU combines the central processing, power supply and discrete I/0 points into a a compact stand alone device.The power supply provides power for the CPU and other expansion modules.

The comminication port allows a programmer any other extrenal devices to be connected. Status light provides visual information about CPU mode (RUN or STOP), current state of I/O s And whether any fault has been detected. An optional plug in serial EPROM cartridge provides means to store programs and transfer from one CPU to another . An optional plug in battery cartridge provide extened retention of data memory in RAM.

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INPUTS AND OUTPUTS POINTS (UNITS):

The I/O units form the interface between the micro electronics of the programmable controller and the real world outside. Hence , it usually has necessary signal conditioning And isolating functions. This terefore allows a PLC to be directly connected to process actuators and transducers without the need for internidiate circuitry.

The inputs and outputs are physically located in one casing itself along with the CPU and therefore is of one type i.e.24 v PLCs are equipped with the standard screw reminals. On every I/O point , allowing rapid and simple removal and replacement of the signals. Every I/O has a unique adress or channel number which is used during program Development to specify the monitoring of an input or the activating of a particular output Within the program indication of the status is provided by light emitting diodes on the PLC Itself making it simple to check the operations of the process output. input and

These input or output can be either discrete or it can be analog type.

MEMORY:
Memory is divided into two parts namely:

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UPGRADATION OF EMA-6 USING SIEMENS S7-200 LOAD MEMORY WORK MEMORY

LOAD MEMORY:
Load memory is used to store the user program without the symbol table and the comments. The load memory can be either RAM, ROM, EPROM OR EEPROM memory depending on the programmable controller.

WORK MEMORY:
Work Memory is used to store the parts of the user program required for program processing . This area is usually backed up by a battery to hold user program for long durations even when the system is switched off.

DOWNLOADING & UP LOADING:

DOWNLOADING:

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Writing the applications program into the CPU memory for programming the required operation is called downloading. The program for down loading must be compiled for errors. The CPU must in operating mode(RUN OR STOP MODE) Before downloading the CPU must be reset to ensure no present. old blocks are

UPLOADING:
Writing the application Program on to the programmer from the CPU memory is called Uploading. Saving information from the programmable controller Fast configuring and editing of the station.

BLOCK DIAGRAM OF PLC:

POWER SUPPLY
I N P U T LOAD MEMORY

O U T P U T
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CPU
WORK MEMORY

SERIAL PORT

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FIELD INPUT DEVIC E

PROGRAMME R

FIELD OUTPUT DEVICE

BASIC PRINCIPLES AND OPERATION OF PLC:

A PLC operates by examining by input signals from a process and carrying out logic instruction which have been programmed into its memory. On this input signal , reducing output signals to drive process equipment or machine . Standard obterfaces built into the PLCs allow them to be directly connected to process actuators and transdurcers without the need for intermediate circuitry or relays.

PLC are purpose built computer consisting of three functional areas , processing , memory and input/output. Basic block diagram of a type PLC system is as shown in figure In addition to the above programming unit is necessary upload control
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to down load or

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Programmed to and from the PLC memory. Virtually all PLC s are micro processor or Micro controller based using micro as the system CPU.

LEADING MANUFACTURES OF PLC SYSTEM:

Allan Bradley Bosch General electric fanue GEC

Siemens Ltd Texas Instruments Tele Mechanique Toshiba

WORKING PRINCIPLE OF INDUCTION HARDENING:

If an AC flows through a colil a magnetic field which varies in strength of the current will be generated this field will be concentrate to the inside of the coil and its magnitude will depend at the strength of the current and number of turns in the coil now if a metal object is placed inside the coil eddy current is induced in the object . Due to the resistance of the material heat will be

Klocner moeller

Westinghouse etc

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UPGRADATION OF EMA-6 USING SIEMENS S7-200 generated in the region through which eddy current flows. The heating effect increases as the field strength increase and will be influenced by the magnetic properties of the metal object & by how closely the coil encircles the object.

The induced current also generate their own magnetic field which is in opposition to the field generated by the coil & which prevents the latter field from penetrating to the centre of the metal object and therefore eddy current will be more active invicinity of the surface and decrease in strength towards the centre of the object.

BLOCK DIAGRAM OF INDUCTION HARDENING:

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INCOMING SUPPLY

SCR CONTROL CIRCUIT

OSCILLATOR CIRCUIT

HV TRANSFORME R

RECTIFIER CONTROL CIRCUIT

DC CONTROL CARDS

MATCHING TRANSFORM ER

ACKNOWLEDGEMENT
The satisfaction that accompanies the succesful completion of any task would be incomplete

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UPGRADATION OF EMA-6 USING SIEMENS S7-200 without mentioning the name of the pepole made it possible , whose constant guidance and encouragement to thank crowned my effort with sucess . first of all i would like

Mr.Chandrashekara(Deputy Manager-instrumentation ,MICO), Mr .C.M.Ashwathappa (Deputy manager MVC,MICO), Mr. Krishna Mohan, Mr. Sendil Kumar, Mr.Manjunath and Mr. Natarajan and all the supporting staff at MICO without whom this project would not have been possible.

This project would not have been possible without the help of number of people and therefore we would like to take this opportunity to extend our gratitude to each one of them of this institution The Oxford College of Engineering.

We thank our Head of the Department, Prof. srinivasan, for his innovative ideas and support and motivation. I thank our Seminar In-charge, Mr.Jayakumar and Mrs. B. Devi Vighneshwari for her efforts and guidance.

We thank all the teaching and non-teaching staff members of the Electrical and Electronics department for providing the necessary help and co-operation.

POKA YOKE:

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POKA-YOKE is a japanese word that means MISTAKE PROFFING. This is a technique first thought by a japanese engineer Mr.SHIGO SHINGO, Which is used to avoid human errors. Following are the three levels of operation System which are indicative in nature. System which rae preventive in nature. System which ensures zero error.

POKA-YOKE is used to obtain zero defects in the products threfore motivating the employees and delighting the customers thus benefiting the organization . POKA-YOKE techniques are normally adopted in officers and in industries . POKA-YOKE Plays a very important role in our project. We employ POKA YOKE technique in the following Places.

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