SCADA System with HMI and Applications (VPL-S7-1500)

The system consists of the following:

PLC Trainer (Siemens) with HMI

PLC Specifications

• SIMATIC S7-1500

Compact CPU CPU 1512C-1 PN, central processing unit with working memory 250 KB for program and 1 MB for data, 32 digital inputs, 32 digital outputs, 5 analog inputs, 2 analog outputs, 6 high speed counters, 4 high speed outputs for PTO/ PWM/frequency output 1. interface: PROFINET IRT with 2 port switch, 48 NS bit-performance, incl. front connector push-in, SIMATIC memory card necessary

• SIMATIC S7- ET200SP Interface Module

Thanks to the MultiFieldbus interface, the SIMATIC ET 200SP can be used in applications that previously utilized only Modbus TCP or EtherNet/IP. MultiFieldbus is also the right solution when an application is implemented with different controllers (field buses) and the I/O system will continue to be used without modification.

ET-200SP has distribution I/O system of 4 digital output, 8 digital input, 2 analog input and 2 analog output with 2 no. of RJ-45 ports.

• 24VDC/ 10amp Power Supply

HMI: KTP 900 Basic

• PROFINET interface
• Display:
  • Design of display: TFT widescreen display
  • Screen diagonal: 9 in
  • Display width: 198 mm
  • Display height: 111.7 mm
  • Number of colors: 65 536
  • Resolution (pixels): 800 x 480 pixel
• Backlighting:
  • MTBF backlighting (at 25°C): 20 000 h
  • Backlight dimmable: Yes
• Control elements: Keyboard fonts
• Function keys:
  • Number of function keys: 8
  • Onscreen Numeric keyboard
  • Onscreen alphanumeric keyboard
• Touch operation:
  • Design as touch screen: Yes; Analog-resistive
• Installation type/mounting: vertical/portrait/landscape
• Maximum permissible angle of inclination without external ventilation: 35°
• Supply voltage: DC

SCADA SOFTWARE

SIMATIC WinCC, a Siemens SCADA (Supervisory Control and Data Acquisition) system, offers features like real-time monitoring, data logging, alarm management, and trend analysis, enhancing industrial process optimization and efficiency.

Here’s a more detailed breakdown of WinCC SCADA features:

Core Functionality:

• Real-time Monitoring and Control: WinCC provides a user-friendly interface for operators to monitor and control industrial processes in real-time.
• Data Acquisition: It collects data from various sensors and devices, enabling operators to track process parameters and identify potential issues.
• Data Logging and Archiving: WinCC allows for efficient data logging and archiving, enabling historical data analysis and trend identification.
• Alarm Management: It offers robust alarm management capabilities, alerting operators to critical events and enabling timely responses.
• Trend Analysis: WinCC facilitates trend analysis, allowing operators to identify patterns and optimize processes.

WORKING MOUDLES FOR PLC:

PICK & PLACE AND STAMPING SYSTEM

The system has following features:

• Complete system mounted on Aluminum Profile Plate with operating console.
• It has dispensing unit, feeding and testing mechanism, detection unit etc. to fulfill the requirements.

The system consists of the following:

• Work Station:
  • Aluminium channels: 1100mm x 800 mm x 700 mm (LxWxH)
• Stepper Motor Drive Unit:
  • Conveyor belts: 2 or as necessary
  • Pick & Place Unit
  • Gripper
• Feeding Unit:
  • Transparent pipe: 3” Dia minimum
  • Pneumatic Cylinder: 16 mm bore x 100 mm stroke
• Material Detecting Unit:
  • Conveyor Belt: 1000 mm x 40 mm minimum
  • IR Sensor
  • Start Sensor
  • Stop Sensor
  • Bins: 4” x 6”
• Power Supply Module:

This module has leakage protection circuit breaker, switching power supply (24V/3A) and tin sockets for external devices to provide DC power and AC single-phase power, and has a leakage, short circuit, overload protection, improve the safety of the equipment.

• Pneumatic Driving System:
  • Pneumatic Solenoid valves, Cylinders, Different
  • Filter Regulator & Lubricator
  • Rated voltage: 220V
  • Rated frequency: 50Hz
  • Motor power: 1.5HP
  • Speed: 2800 RPM – No load speed
  • Tank capacity: 25 Ltr.
  • Auto Cutoff
  • Over pressure safety valve
  • ON/OFF Valve
  • Pressure Gauge

BOTTLING PLANT

It consists of a stepper motor controlled Rotary mechanism, power supply, solenoid valve, tank, one proximity sensor and one optical sensor to study the concepts of bottle filling in a station by PLC.

Specification

• One proximity sensor to detect the bottle position.
• A mechanical base fixed with stepper motor provided to hold 4/6 bottles and rotate in circular motion.
• One tank provided to hold liquid.
• One solenoid valve to control the volume of liquid flow into the bottle.
• Reservoir tank with FHP pump to feed the water to supply tank.
• Relay to control the motor
• Logic level: 24V
• Nozzle to fill the bottles
• Stand with castor wheels
• Interface to PLC

RATIO CONTROL

Ratio control in process control maintains a desired ratio between two or more flow rates, often used for blending or mixing streams to achieve a specific composition or property.

Ratio control is a feed-forward control strategy used to maintain a desired ratio between two process variables, often flow rates, by controlling one in proportion to the other, enabling students to learn about advanced control techniques.

The PLC can also monitor the process variables, providing feedback to the control system and allowing for adjustments as needed.

Features

• Controls the ratio of two liquids
• Pumps – 2 Nos.
• Tanks – 3 (around 50/100 liters)
• Stand with castor wheels
• Solenoid Valves – 3 Nos.
• PVC Pipe
• Flow sensors
• Gravity liquid flow sensor
  • Operating voltage: DC 3.5-24V
  • Operating current: >10mA (DC 5V)
  • Output mode: NPN Pulse signal
  • Flow range: 30 – 3000 L/hr
• Flow Control Valve
  • 2 way x CS x SS
  • Flanged ASA 150
  • Diaphragm operated
  • Pneumatic control
• Jointer
• Interface to PLC