Daniel Adams-Zarate & Levi Martin

Project
Proposal
Organic
Chocolate
Ltd
September 27
2011

Industrial
Automation Ltd
The Challenge

Organic Chocolate Ltd has recently updated most of their plant to include communication and
remote input capability, and now wish to automate the plant using ABB PLC.

Unfortunately a contractual issue has stopped the original contractor from finishing the work and his
lawyers have instructed him to hold back the design and wiring drawings.

Industrial Automations challenge is to complete the set up on their new automated chocolate
manufacturing line.
Brief

The recipe for Organic Chocolate Ltd is a mixture of: 100kg of cocoa powder, 1.5kg of emulsifier and
50kg of palm oil.

The Cocoa powder is added to the mixing vessel by operating the hopper slide ram until the weight
of the vessel has reached 100kg.

The hopper slide ram closes, the mixer motor is started and the palm oil valve is opened until 50kg is
added to the mix. The palm oil valve is closed.

Emulsifier valve opened 1 minute later to allow 1.5kg of emulsifier to be added. Emulsifier valve
closes.

The mixer must continue for an additional 7 minutes 35 seconds. The mixer is then lifted out of the
vessel and the process stops for 20 minutes to de-aerate.

The #1 drain valve is then opened to allow the mixture to drain onto the chocolate molding machine;
a signal is sent to the chocolate molding machine to start operating when the vessel is empty, and
the cleaning cycle begins.

The cleaning cycle requires that the mixer is lowered and started rotating; 200L of water added to
the vessel and allowed to be stirred for 5 minutes.

The #2 drain valve is opened until the vessel is empty. The drain valve is closed and the cycle is reset.

The process is to be displayed as visualization available to production staff so that they see the
status of production at any time.












Cocoa Powder Silo
500kg Capacity
Hopper Slide
Ram
Mixer Lift Ram
Mixer
Motor
Palm Oil
Reservoir
Emulsifier
Water Mains
Pipe
Mixing Vessel
Drain 2
Drain 1
250l 20l
1
10
8
6
12 13 14
11
15
2
16
3 4
7
9
5
17
Siren Alarm
Legend:
1 Cocoa Level sensor
2 Strain Gauge
3 Palm Oil Ultrasonic Sensor
4 Emulsifier Ultrasonic
Sensor
5 VSD (Motor Speed)
6 Hall Effect Sensor (Motor
Speed)
7 Upper Ram Limit Switch
8 Mid Ram Limit Switch
9 Lower Ram Limit Switch
10 Hopper Slide Ram (Cocoa
Powder)
11 Lift Ram
12 Palm Oil Valve
13 Emulsifier Valve
14 Water Valve
15 Drain Valve 1 (Mould
Machine)
16 Drain Valve 2 (Waste)
17 Siren Alarm/GSM Alarm
18 Safety Guard Sensor
18
Fig 1: Mixer Schematic
Technical Solution
Features:

Speed Control and Direction to mixer motor
Variable speed for cleaning cycle
Time-out for filling process (alarm if filling takes longer then preset time)
Variable input for total batch weight (percentage based)
Human Machine Interface (HMI) for operating staff
Isolation On/Off switch (Process is not compromised)
Emergency stop

Process:

The Main Process is illustrated below; it shows the whole process in sub routines. This would be
similar to how it would look like in CFC, except there would be no arrows and the boxes would be
labelled in chronological order.

Main Process
Auto Start Process
Check Status of
operation
Add ingredients and
start mixing process
De-aerate process
Drain process
Send signal to
moulding
machine
Cleaning cycle
The Auto start sub routine is shown below. It would also be programmed in CFC with complex parts
called up in structured text or instruction list.
Description is included below.
(From restart)

1) Welcome Screen

2) All timers and counters and temporarily variables are reset

Auto) User will be directed to a new screen which will allow the user to choose the settings they
want.

Settings: Amount of cycles, Manual confirmation after cycle, problem notification, motor speed,
motor direction, cleaning cycle mode, net batch mix (percentage based), Alarm time outs, empty
level, and HMI activation settings will only be applied if they fall within the limits of the code, which
is pre-defined by the programmer.

(From cycle)

3) Reset all temporary counters and timers

4) Chosen settings will then be applied and program will move to sub routine "check status of
operation"










Auto start process
Home Screen
Chooses automatic
settings
Check status
opperation
The Check status of operation is shown below. It would also be programmed in CFC with complex
parts called up in structured text or instruction list.
Description is included below.
Check Status of operation

1) Diagnostic window pops up on HMI which will display the process
2) Will check status of Safety interlocks, switches, strain gauge with-in limits
2b) If there is a problem with any of these functions, problem LED will be lit and fault shown on HMI,
Process is then paused
2C) Operator will then have to acknowledge problem, and see if they can fix the problem

If problem can be fixed
2d) Operator will press confirm then program will jump back to 2 and check all the statuss' again
from the beginning

If problem cannot be fixed
2e) operator will press the shutdown function, the problem will be logged and the Design Engineer
will be sent an automatic message with the problem log. Operator will then be able to lock out the
machine

3) Will check levels of Cocoa powder, palm oil and Emulsifier

If problem can be fixed
3b) Operator will press confirm then program will jump back to 3 and check all the statuss' again
from the beginning

If problem cannot be fixed easily
3c) operator will press the shutdown function, the problem will be logged and the problem can be
sorted while offline
Check status of opperation
Check Status of
operation
Every process
ideal
Display problems
Problem Fixed
Home screen and
problem logged
Add ingredients and
start mixing

4) Continues to next subroutine "add ingredients and start mixing"

The Add ingredients subroutine is shown below. It would also be programmed in CFC with complex
parts called up in structured text or instruction list.

Description is included below.

Add ingredients and start mixing

1) Cocoa powder slide ram is opened and cocoa is added

2) Strain gauge measures amount of cocoa required and closes ram at required amount

Add ingredients
Add ingredients and
start mixing
Add coca powder
Start mixing
Palm oil and
Emulsifier added
Finish Mix
De-aerate process
2b) If strain gauge measures increase in weight above the required amount and keeps increasing,
problem LED is lit and alarm is sound. Problem is logged and process is STOPPED and reset

2c) If strain gauge measures increase in weight above the required amount and stops increasing,
problem LED is lit and dependent on mode, Problem will be solved.

2d) If strain gauge measures decreasing weight or no weight gain during filling then problem LED is
lit and alarm is sound, and problem is Logged and process STOPED and reset.

2e) if strain gauge measures underweight after ram is closed then it will slowly increase weight by
opening hopper slide ram until the correct weight is achieved.

3) Start mixing at chosen motor speed.

4) Add palm oil has been added to chosen amount (still mixing)

4b) If strain gauge measures increase in weight above the required amount and keeps increasing,
problem LED is lit and alarm is sound. Problem is logged and process is STOPPED and reset

4c) If strain gauge measures increase in weight above the required amount and stops increasing,
problem LED is lit and dependent on mode, Problem will be solved.

4d) If strain gauge measures decreasing weight or no weight gain during filling then problem LED is
lit and alarm is sound, and problem is logged and process STOPED and reset

4e) If strain gauge measures underweight after the valve is closed then it will slowly increase weight
by opening the valve until the correct weight is achieved

5) Once correct amount of palm oil has been added mixer starts timer 1 (1 min) (still mixing)

6) Once timer 1 expires emulsifier is added to required amount

6b) If strain gauge measures increase in weight above the required amount and keeps increasing,
problem LED is lit and alarm is sound. Problem is logged and process is STOPPED and reset

6c) If strain gauge measures increase in weight above the required amount and stops increasing,
problem LED is lit and dependent on mode, problem will be solved.

6d) If strain gauge measures decreasing weight or no weight gain during filling then problem LED is
lit and alarm is sound, and problem is Logged and process STOPED and reset

6e) If strain gauge measures underweight after the valve is closed then it will slowly increase weight
by opening the valve until the correct weight is achieved

7) Once correct amount of emulsifier is added timer 2 is started (7 min 35 sec) (still mixing)

8) Once timer 2 is done, start sub routine "De-aerate process"


Note; If motor fault or mixer lift ram occurs will operating in this sequence then process is stopped
and alarm is sent and problem is logged, problem could then be resolved and process resumed or
process could be shutdown.

The De-aerate process is shown below. It would also be programmed in CFC with complex parts
called up in structured text or instruction list.
Description is included below.
De-aerate Process

1) The mixer is lifted halfway and the motor is spun to remove excess mix off its blades. Then mixer
is lifted all the way out

2) Timer 3 is then started (20 min)

3) Once timer 3 is done then "Drain process" subroutine is called

Note; If the mixer lift ram fails, then process is stopped and alarm is sound, problem is logged. If
problem can be fixed process, will be resumed if not process will be reset and shutdown.






De-aerate process
De-aerate process
Mixer lifted out
Wait 20 minutes
Drain process
The Draining process is shown below. It would also be programmed in CFC with complex parts called
up in structured text or instruction list.
Description is included below.

Draining process

1) Drain valve #1 is opened and mixture is drained into molding machine

2) Strain gauge periodically checks if mixture has decreased to 'empty' level

2b) By the 'x' check and strain gauge records 'little' to no decrease in weight then, alarm is sound,
process is stopped and problem logged.
If problem can be fixed process will be resumed, if not process will be reset and shutdown.

3) Signal is then sent to molding machine

4) Drain valve #1 is then closed and then "cleaning cycle" is started




Draining process
Drain process
Drain valve is
opened
Mixture drained
Cleaning cycle
Signal sent to
moulding
machine
Valve closed
The cleaning cycle is shown below. It would also be programmed in CFC with complex parts called up
in structured text or instruction list.
Description is included below.

Cleaning cycle

1) Mixer lowered and motor started according to 'cleaning setup'

2) Water valve is opened and 200kg of water is measured by strain gauge then water valve is closed

2b) If strain gauge measures increase in weight above the required amount and keeps increasing,
problem LED is lit and alarm is sound. Problem is logged and process is STOPPED and reset

2c) If strain gauge measures increase in weight above the required amount and stops increasing,
drain valve #2 is opened until the correct weight is obtained.
Cleaning cycle
Cleaning cycle
Mixer lowered
Water added
Mixer started
Clean process
Manual/Auto start
process
Task Mapping I/O Type Address Description
Strain Gauge strain Analogue_In %IW2001 (0-10V) Loop Suplied Pressure Sensor
Hall-Effect Sensor motor_s Digital_In %IX4000.0 Fast Counter Pulse Speed Sensor
Up Limit Switch up_ram Digital_In %IX4000.1 Mixer Lift Ram Home Position
Mid Limit Switch mid_ram Digital_In %IX4000.2 Mixer Lift Ram Cleaning Level Height Sensor
Low Limit Switch low_ram Digital_In %IX4000.3 Mixer Lift Ram Mixing Process Position
Motor Fault m_fault Digital_In %IX4000.4 Temperature/Failure
Safety Guards safety_g Digital_In %IX4000.5 4-Switches, input is common
E-Stop Switch e_stop Digital_In %IX1.0 Emergency Stop Switch (Process Stop)
On/Off Toggle Switch on/off Digital_In %IX1.1 Main Switch
Motor PWM pwm Digital_Out %QX0.0 Motor Speed Control
Cocoa Slide Ram slide_ram Digital_Out %QX0.1 N/C Spring Return
Mixer Lift Ram mixer_ram Digital_Out %QX0.2 N/up Hydraulic Return
Palm oil Valve palm_v Digital_Out %QX0.3 N/C Spring Return
Emulsifier Valve emul_v Digital_Out %QX0.4 N/C Spring Return
Water Valve water_v Digital_Out %QX0.5 N/C Spring Return
Drain Valve #1 valve_1 Digital_Out %QX0.6 N/C Spring Return
Drain Valve #2 valve_2 Digital_Out %QX0.7 N/C Spring Return
Siren Alarm/GSM Alarm alarm Digital_Out %QX1.6 Emergency Warning System
Maintenance LED maint_led Digital_Out %QX1.1 Periodic Maintenance Indicator
Fault LED fault_led Digital_Out %QX1.0 Process Fault Indicator
Motor F/R m_f/r Global_VAR nil Motor Direction Control
Cocoa Level Sensor cocoa_s Global_VAR nil (4-20mA) Loop Supplied Pressure Sensor
Palm oil Level Sensor palm_S Global_VAR nil UltraSonic Sensor
Emulsifier Level Sensor emul_s Global_VAR nil UltraSonic Sensor

2d) If strain gauge measures decreasing weight or no weight gain during filling then problem LED is
lit and alarm is sound, and problem is logged and process STOPED and reset

2e) If strain gauge measures underweight after valve is closed then it will slowly increase weight by
opening the valve until weight is achieved

3) Timer 4 is started (5 min)

4) Once timer 4 is done drain valve #2 is opened and water is drained

5) Strain gauge will periodically measure the weight of the remaining water and if 'little' or no
decrease in weight is achieved within 'y' cycles then alarm is sound process is stopped problem is
logged. If problem can be resolved then process will be resumed if not process is STOPPED and reset.

6) Valve #2 is then closed and Cycle decrements it job list by 1 cycle and returns to "home screen"
(cause of cycle count returns to cycle point)
I/O List