International Journal of Scientific & Engineering Research Volume 9, Issue 6, June-2018 969

ISSN 2229-5518

Implementation of a Four-Floor
Programmable Logic Controlled Elevator
System
KAMALU, U.A, OGUNLEKE, F.A
[email protected] [email protected]

ABSTRACT: This paper is on the design and implementation of a 4-Floor Elevator control system
using Programmable Logic Controller (PLC). It involves developing a model of the Four-Floor and
simulating the control using a SCADA system. The PLC in consideration is Siemens S7-200 with
minimum of 14 inputs and 10 outputs, and the SCADA system in use is Intouch Wonderware,
Schneider Electric product software. The elevator operates in a power saving mode; resulting in the
use of an intelligent design model. The elevator control system is programmed in a ladder diagram
format into the PLC. The design gives the basic structure, control principle and realization method of
the PLC control system in details. It also presents the ladder diagram of the key aspects of the
system. The system has simple peripheral circuit and the operation result showed that it enhanced the
reliability and performance of the elevators. Some suggestions on how to extend this system to the
control of more than four floors are also included. It contributes to the design and use of simple
circuit, easy to understand, operate and use.

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Keyword: Controller, Elevator, Ladder, Logic, Programmable, SCADA

1 INTRODUCTION be transported, desired passenger waiting

With the development of architecture times and frequency of use.
technology, the building structures are taller
and elevators become important vertical This paper elaborates the design and
transportation vehicles in high-rise buildings. implementation of an elevator that is
For most people in urban cities, elevators have controlled using Programmable Logic
become an integral part of their life. Simply Controller (PLC).
stated, an elevator is a hoisting or lowering
With latest developments in science and
mechanism, designed to carry passengers or
technology, PLC technologies have been
freight, and is equipped with a car and
widely applied in industrial control. A lot of
platform that typically moves in a fixed guides
factory production lines, processing
and serves two or more landings. They are
equipment, ship loading and unloading device
responsible to transport passengers, living/
and the operation of elevators are controlled
working or visiting in the building,
by the PLC, as long as the scheduled control
comfortable and efficiently to their
tasks are compiled in the form of a string of
destinations. So the elevator control system is
instructions and stored in the memory. It is the
essential in the smooth and safe operation of
job of PLC to drive the output devices in
each elevator. It tells the elevator in what order
response to input signals present at its input
to stop at floors, when to open or close the
ports.
door and if there is a safety-critical issue.
PLC applications in elevator systems have
Hydraulic and roped elevators are the two
been established to be one of the most potent
types of elevators in use today. The main
means of elevator control. PLC acts as the
design considerations for choosing either
master controller. It collects a variety of input
electric traction drive or hydraulic for a
signals of the elevator, including the location
particular project are the number of floors, the
of the elevator, state of the signal of internal
height of the building, the number of people to
and external command button, the door lock
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International Journal of Scientific & Engineering Research Volume 9, Issue 6, June-2018 970
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signal, the door zone signal, forced to slow 2.1.1 Design of Elevator Cabin
down, the signal within the wells and fire The elevator cabin is used to transport person
signals. Based on the input signals to the and goods. It is a small enclosure with
elevator, which could be the elevator floor transparent window where persons enter and
signal, speed signal, switch gate signal, are protected before the elevator moves on.
directional relay signal or brake relay signal, The elevator cabin is designed by having in
the programmed logic runs a calculation to mind the number of passengers it is going to
enable it control the operations of the elevator. accommodate. Also it should have the capacity
to bear the weight of the passengers travelling
in the elevator. The proposed elevator is
having the capacity to accommodate
2. METHODOLOGY
approximately 10 persons of 65 kg each
The design of the elevator control system
consists of two main parts; hardware and Maximum No. of passengers that can be
software design. The limit switches and push accommodated in the cabin = 10
buttons are primary part of the system. They Approximate weight of each person = 65 kg
send signal to the PLC, which in turn; based Maximum weight that the cabin can handle = 650 kg
on these input signals and the code To accommodate persons the cabin has been
implemented in it, generate the appropriate designed with the following dimensions:
output to the pulley and door motors. L x W x H …………………………………………….1

The important part of the system is the This dimension (1.5 m x 1.5 m x 2 m) will

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controller and the type of controller used here give a total volume of 4.5 m3. This is assumed
is PLC which is configured to control the to accommodate a total of 10 persons with
operations of the elevator. Electromagnetic average volume occupancy of 0.45 m3. Also,
actuator and contact action were so slow, considering the total weight of 650KG the
mechanical and electromagnetic components cabin can handle, by introducing allowance of
have large inertia. Therefore, the control +50kg, a maximum weight of 700kg is in
precision of system was difficult. So there is a consideration. This total weight and the
need to go for modern type of controllers like volume will guide in selecting the base support
PLC. and the rope strength to carry the cabin and the
passenger without failure.
In this type of control there is provision to
monitor the entire system by means of 2.1.2 Base Plate Support Calculation and
SCADA (Supervisory Control and Data Selection
Acquisition) system. The first and most important step towards
2.1 Elevator Hardware Design successful selection of plate for use is the
proper understanding of its application.
The design of the elevator system will be Besides the calculation, the property
based on the calculation of certain parameters requirements for plate applications in elevator
which defines the operation of an elevator. To designs are considered. The main properties
meet the objectives of the elevator system, include; corrosion resistance, oxidation
theoretical studies of its operation and the resistance, strength and ductility, suitability for
machine model of an ideal elevator was internal fabrication, stability in service,
considered. Then to validate and to implement thermal conductivity, thermal expansion,
the simulated model as a prototype, certain electrical resistance and rigidity among others.
calculations have been carried out to determine
some critical parameters. The parameters The required thickness of the base plate can be
include the size of the cabin, maximum calculated as follows:
number of persons that can be accommodated The cabin has been designed to take a
in the elevator, strength of the rope, base plate maximum weight of 700kg. Having in mind
design, type of motor used, motors power the area coverage for 10 persons in the cabin
rating and torque rating. which gives a volume of 4.5 m3 giving the area
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International Journal of Scientific & Engineering Research Volume 9, Issue 6, June-2018 971
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2
as 2.25 m , and considering tensile strength From the rope manufacturer’s data sheet Table
that can withstand a force of 700kg x 9.8m/s2 1, to meet the design requirement, the cable
(6.86KN). According to plate selection table with 10.9kN safe load capacity and thickness
by Solid-Liquid Filtration and Separation of 3/8” or 9.5 mm is considered.
Technology, the plate minimum thickness will
be 10mm and the maximum thickness will be
30mm.
2.1.4 Power Calculation for Motor
The motor used here is a capacitor start single
For the sake of design simplicity the entire
phase induction motor. Based on the design
system has reduced to a prototype of 1:20 ratio
specification the output power and the output
to the real model.
torque of the motor are calculated by a simple
calculation.
2.1.3 Rope Strength
The tension on the rope and its choice of Power and torque calculation
selection can be determined with the following Weight of empty cabin = 100 kg
simple calculation. The force exerted on the
Counter weight = 100 kg
rope can be found by using Newton’s formula.
10 persons with 65 kg each = 650 kg
F = mass x acceleration = mg……………..…..2
For constant speed operation of 1 m/s or 60 m/min
The expected entire weight of the elevator when
The power, work and force are calculated as
fully loaded will be: follows:

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10 persons with 65 kg each = 650 kg Power = Work × Time…………………………..…3
Cabin weight = 100 kg
Work = Force × Distance…….………………..….4
Counter weight = 100 kg
Force, F = mg…………………………………...…..5
F = (650+100+100) x 9.8 = 8330 N = 8.33kN
𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒
The force acting on the string is 8.33kN. So a Power = Force × ………...……………….6
𝑡𝑖𝑚𝑒
string with the capacity to bear at least 9kN has to
Power = Force × Velocity ………...………….7
be chosen on the standard rope strength in table 1.
Force = 650 × 9.8 = 6370 N
Table 1: Rope Strength Table Power = 6370N × 1m/s = 6370 W

But 1hp = 745 W

6370
Therefore 6370 W will be = 8.55hp
745

This can be approximated to 9hp or 6705 W

Rotational Speed, ω = 1500 rpm

The torque of the motor can be calculated by using

the following expression:
𝑃𝑜𝑤𝑒𝑟 𝑖𝑛 𝑊𝑎𝑡𝑡𝑠
Torque of the motor (Nm) = …….…8
2𝜋𝜔

6705
= = 31.5 Nm
2𝜋 𝑥 1500

BUT with the prototype ratio of 1:20

Weight of cabin = 5 kg

Counter Weight = 5 kg

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10 persons of 3.25 kg = 32.5 kg For smooth meshing of gears, both the gears
should have same sized teeth and invariably have
For constant speed operation of 1 m/s = 60 m/min the same pitch, p.
The power, work and force are calculated using The pitch can be calculated using the equation (10)
the equations 3 to 7.
2𝜋𝑟𝑑1 2𝜋𝑟𝑑2
P= = ………………………….10
F = 32.5 x 9.8 = 318.5 W 𝑁𝑑1 𝑁𝑑2

But 1 hp = 745 W Take the number of teeth to be 8 (1 tooth for every

45 degree)
Therefore 318.5 W = 0.427 hp which is 4
approximately 0.5 hp 0r 372.5 W P = = 0.5
8

Rotational Speed, ω = 1500 rpm From ‘p’ the value of Nd2 can be found out
𝑃𝑜𝑤𝑒𝑟 𝑖𝑛 𝑊𝑎𝑡𝑡𝑠 2𝜋𝑟𝑑2 30
Torque of the motor (Nm) = Nd2 = = = 60 teeth
2𝜋𝜔 𝑝 0.5
372.5
= = 1.749 Nm Therefore, the gear ratio is given by
2𝜋 𝑥 1500

2.1.5 Gear Calculation R = Nd1: Nd2 = 8:60 = 1:7.5

To achieve the desired speed of 1 m/s from the 2.2 Controller Hardware Design and
motor output of 1500 rpm, the diameter and Configuration

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the circumference of the gears has to be
When an engineer is embarking on any
calculated thus;
program of automation, it must be
Cabin weight = 100kg remembered that the controller is only a tool
used to perform the necessary tasks. The actual
Counter weight = 100kg task of implementing automation is therefore
paramount, often involves many
10 persons with 65kg = 650kg
methodologies in its system design phase.
Speed of the elevator is 1 m/s Once the specifications are established, the job
of selecting a suitable controller will then
= 60m/min = 6000cm/min become most important as this would
Circumference of gear 2, c2 = 30cm
determine how at ease the automation program
might continue.
30
Therefore, diameter of gear 2, d2 = = 9.5 cm
𝜋 There is a massive range of PLC systems
To find the rpm of gear:
available today, with new additions or
replacements continually being produced with
𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 enhanced features of one types or another.
rpm = ………………….9
𝑐𝑖𝑟𝑐𝑢𝑚𝑓𝑒𝑟𝑒𝑛𝑐𝑒
Advances in technology are quickly adopted
6000 by manufacturers in order to improve the
Speed of gear 2 = = 200 rpm
30 performance and market status of their
However, the speed of gear 1 is 1500 rpm products. However, irrespective of make, the
majority of PLC in each size range is very
Speed and length are inversely proportional similar in term of their control facilities.
200 𝑐1
Where significant differences are to be found
Therefore, = Circumference of gear1 = is in the programming methods and languages,
1500 30
together with differing standards of
c1 = 4cm manufacturer support and backup.
𝑐1 With the vast choice of equipment now
This implies, the diameter of gear1, d1 =
𝜋 available, the engineer can usually obtain
4 similar systems from several original
= = 1.273 𝑐𝑚 equipment manufacturers (OEM). When the
𝜋

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specification requires certain types of function
or input/output, it is possible that one system
from a single manufacturer standing out as
more superior or cost effective than the other;
but normally this is rarely the case.

To determine the most suitable PLC to be used

in the automation task, there are several basic
considerations to be made:
 Necessary input/output capacity;
 Types of I/O required;
 Size of memory required;
 Speed and power required of the CPU
and instruction set
 Manufacturer's support and backup. Figure 1 Elevator Control Algorithms

Based on these considerations; and having 2.4 Software Design Logic

carefully considered features of most of the
PLCs; Siemens STEP S7-200, CPU 224 PLC For a four-floor control system, the control

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has been choosen. It has 14 input pins and 10 software has been designed in such a way that
output pins and it matches the I/O each floor has its own control software block;
requirements of this design work. in this way tasks will be performed in
accordance with the particular location of the
lift vehicle. This enables the design to be
logically organized and, in addition, determine
2.3 Elevator Control Algorithm and what routine to run in response to a particular
Software Development input signal at different locations of the lift
vehicle. The block diagram of the software
The main aims of the elevator control system
design is shown in figure 2
are:

• To bring the lift car to the correct floor.

• To minimize travel time.
• To maximize passenger comfort by
providing a smooth ride.
• To accelerate/decelerate and travel
within safe speed limits.
Figure 1 shows the control algorithm of a
typical elevator control system. This can be
applied to any system of elevator control

Figure 2 Software Design Block Diagram

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Each block of the above mentioned blocks has 2.5 Overview of Implementation
been itself divided into three minor blocks and Techniques
these are: Block register initialization,
Destination scan and Push Button Scan. Any kind of programming style to be adopted
must ensure that tasks are achieved by
2.4.1 Block Register Initialization assigning values to the registers or
setting/resetting bits in different registers. This
The function of this block is to make sure all design is not an exception to that. For
the starting parameters are in the desired states example, the Register Initialization block is
when the car enters a particular floor block. As composed of a series of bit set/reset
an illustration, when the elevator is on the first instructions or assignments of a full byte value
floor, location initialisation needs to be set to to a particular register. Travels from floor to
this floor. When the system is just powered on, floor or door open/closure delays are achieved
the vehicle should be in a static state (not through Ladder Logic implementations.
moving) and it does not make sense to say that
the direction is up or down since there is no The control algorithms developed in
motion at all. The doors are sealed and at the the process of implementing the software
moment the system has not been instructed to design are translated into ladder logic for
go anywhere. The above mentioned effective design analysis. Based on these
information has to be entered into the requirements, the logic has to be developed
controller in form of instructions. These accordingly with the specifications of the PLC
instructions have been organized into one set chosen. For the working model of an elevator,

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that is referred to as Register Initialization various logics for different operations have to
block since they are entered into the system by be developed and it is discussed in the
assigning values to registers. subsequent subtitles.
2.4.2 Destination Scan The flowchart in Figure 3 achieves the floors
The Register Initialization block sole role is to register initializations and destination scans.
tell the system where it is, or to set the starting
point in the particular floor block. The next job
is to check whether there are instructions to go
anywhere. If there are any destination request
the system should run routines to go to that
particular destination. If no requests are
available, the system should keep looping in
this section, looking for a destination until it
finds one.
2.4.3 Push-Button Scan
So far, the system knows its position or
location and it knows how to look for a
destination; this section is concerned with
finding a way to give the system a destination.
From the hardware design section signals are
entered through Push-Buttons. Depending on
the location of the lift vehicle, when a
particular destination request PB is engaged,
appropriate registers should be set. With the
destination set, the Destination Scan block
should find it and appropriate routines should
be run.

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15. EMERGENCY STOP - I1.6
16. MANUAL DOOR OPEN/CLOSE - I2.0
Output Assignment
1. PULLEY UP MOTOR SIGNAL - Q0.0
2. PULLEY DOWN MOTOR SIGNAL - Q0.1
3. MOTOR STOPS SIGNAL - Q0.2
4. DOOR OPEN SIGNAL - Q0.3
5. DOOR CLOSE SIGNAL - Q0.4
6. BCD TO 7 SEGMENT DISPLAY - Q0.5
7. BCD TO 7 SEGMENT DISPLAY - Q0.6
8. BCD TO 7 SEGMENT DISPLAY - Q0.7
9. BCD TO 7 SEGMENT DISPLAY - Q1.0
Memory Assignment
1. FLOOR 1 MEMORY LOCATION - M0.0
2. FLOOR 2 MEMORY LOCATION - M0.1
3. FLOOR 3 MEMORY LOCATION - M0.2
4. FLOOR 4 MEMORY LOCATION - M0.3
5. FLOOR 1 LAST VISIT MEMORY - M0.5
6. FLOOR 2 LAST VISIT MEMORY - M0.6
7. FLOOR 3 LAST VISIT MEMORY - M0.7
8. FLOOR 4 LAST VISIT MEMORY - M1.4
9. FLOOR 1 VISIT MEMORY - M1.0
10. FLOOR 2 VISIT MEMORY - M1.1
11. FLOOR 3 VISIT MEMORY - M1.2
12. FLOOR 4 VISIT MEMORY - M1.3

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The program is analysed by networks
arrangement and there are four major design
considerations for the control parameters in
this design.
2.6.1 Floor Limit Switch Sensor Design
Figure 3 Initialization and Scan Flowchart
Each floor is designed with limit switch as
2.6 Ladder Logic Implementation sensor and each sensor is assigned a memory
location for proper interlock in the process of
The Siemens SIMATIC micro/win program is
design manipulations. The following networks
used in the project to develop the logic which
describe the sensor designs for floor 1 to floor
controls the PLC using the ladder diagram
4 respectively. The safety interlock design in
language. The following is detailed
each of the floor shows that whenever the
explanation for each and every network in the
limits switch memory of any floor is at “SET”
ladder diagram used to implement the
position; all other memories are at “RESET”.
elevator's software. However, the following
highlights the addresses locations for the
inputs, outputs and the memory assignments.
Input Assignment
1. FLOOR 1 LIMIT SWITCH - I0.0
2. FLOOR 2 LIMIT SWITCH - I0.1
3. FLOOR 3 LIMIT SWITCH - I0.2
4. FLOOR 4 LIMIT SWITCH - I0.3
5. FLOOR 1 CAR CALL - I0.4
6. FLOOR 2 CAR CALL - I0.5 Network1: Floor 1 Limit Switch Sensor design
7. FLOOR 3 CAR CALL - I0.6
8. FLOOR 4 CAR CALL - I0.7
9. FLOOR 1 HALL CALL UP - I1.0
10. FLOOR 2 HALL CALL UP - I1.1
11. FLOOR 2 HALL CALL DOWN - I1.2
12. FLOOR 3 HALL CALL UP - I1.3
13. FLOOR 3 HALL CALL DOWN - I1.4
14. FLOOR 4 HALL CALL DOWN - I1.5
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Network 6: Second Floor Call

Network2: Floor 2 Limit Switch Sensor design

Network 7: Third Floor Call

Network 3: Floor 3 Limit Switch Sensor

design
Network 8: Fourth Floor Call
2.6.3 Motor Pulley Up and Down

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Movement Design

Network4: Floor 4 Limit Switch Sensor design

2.6.2 Hall and Car Call Design
There are two kinds of calls in the elevator
they are hall call and car call. The hall call is
when the pushbutton in the control panel
outside the elevator cabin is pressed. When the
pushbutton on the control panel which is
inside the elevator car is pressed that is the car Network 9: Pulley up – Car Upward Direction
call. The inputs addresses denoted by I0.4,
The ladder network above describes the
I0.5, I0.6 and I0.7 are for Car call request.
situations in which a signal to move the pulley
Similarly, the inputs addresses denoted by
up is made (Q0.0=1), which are:
I1.0, I1.1, I1.2, I1.3, I1.4 and I1.5 are for Hall
call request which can either be upward call or
 If the car was currently residing at the
downward call as indicated in the ladder
first floor (M0.0=1) and a call for the
representation.
second, third, or fourth floor (M1.1=1,
M1.2=1, or M1.3=1) respectively is
made.
 If the car was at the second floor
(M0.1=1), AND a call for the third
floor (M1.2=1) OR the fourth floor
Network 5: First Floor Call
(M1.3=1), AND there was no call for
the first floor (M1.0=0) OR if there
was a call to the first floor (M1.0=1)
BUT the last visited floor was the first
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floor (M0.5) then the pulley has to BUT the last visited floor was the
move up for the sake of conserving fourth floor (M1.4) then the pulley has
power. to move down for the sake of
 If the car was at the third floor conserving power.
(M0.2=1), AND the fourth floor called  If the car was at the second floor
for the car (M1.3=1), AND there was (M0.1=1), AND the first floor called
no call from either the first floor for the car (M1.0=1), AND there was
(M1.0=0) or the second floor (M1.1=0) no call from either the fourth floor
the pulley goes up. OR if there was a (M1.3=0) or the third floor (M1.2=0)
call to the first floor (M1.0=1) OR the the pulley goes down. OR if there was
second floor (M1.1=1) BUT the last a call to the fourth floor (M1.3=1) OR
visited floor was the first floor the third floor (M1.2=1) BUT the last
(M0.5=1) OR the second floor visited floor was the fourth floor
(M0.6=1) then the car has to answer (M1.4=1) OR the third floor (M0.7=1)
the request of the higher floors and then the car has to answer the request
continue moving up to reduce power of the first floor and continue moving
consumption. up to reduce power consumption.
When the pulley up signal is set (Q0.0=1), the When the pulley up signal is set (Q0.0=1), the
pulley down signal(Q0.1) and the motor stop pulley down signal(Q0.1) and the motor stop
signal(Q0.2) are reset (to 0) to ensure that the signal(Q0.2) are reset (to 0) to ensure that the
motor driving the pulley stops and reverse motor driving the pulley stops and reverse
direction if the pulley was not at standstill direction if the pulley was not at standstill

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position and was moving in the opposite position and was moving in the opposite
direction. direction.

Network 11: Motor Stop Reset

The purpose of ladder network above is to
reset the motor pulley up and pulley down
signals whenever the motor stop signal is set;
it is a locking mechanism to ensure that the
motor does not move while the car is loading
Network 10: Pulley Down – Car Downward and unloading passengers.
Direction
2.6.4 Door Automation Design
The ladder network above describes the
The networks in this section describe the door
situations in which a signal to move the pulley
opening and closing actions. When the motor
down is made (Q0.1=1), which are:
stop signal is set (Q0.2=1) a timer is set (T32)
 If the car was currently residing at the
which counts 5 seconds then sets a signal
fourth (M0.3=1) and a call for the
(T32) after that. The need for this counter is
first, second, OR third floor (M1.0=1,
first to ensure the car has come to stand still
M1.1=1, or M1.2=1) respectively is
position since there will be car movement even
made.
after the motor stops for few seconds. This
 If the car was at the third floor
movement is taken into account and therefore
(M0.2=1), AND a call for the second
the motor is signalled to stop once it passes by
floor (M1.1=1) OR the first floor
the limit switch which is fixed at a location
(M1.0=1), AND there was no call for
few millimetres below the actual floor level.
the fourth floor (M1.3=0) OR if there
The time that takes the car to stop from the
was a call to the fourth floor (M1.3=1)
moment the motor is signalled to stop is
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International Journal of Scientific & Engineering Research Volume 9, Issue 6, June-2018 978
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enough to make the car reach the actual floor
level.
3 RESULTS AND DISCUSSIONS
To obtain results for this system in a readable
way; several scenarios covering all potential
usage of the system were tested in both
software simulators and hardware
implementation. Software testing, involves
Network 12: Motor Stop/Door Open Time only test for sequential events, but concurrent
Delay events (events that typically occur on normal
usage of the elevator) could not be tested by
simulation since the simulator used cannot
provide this feature. But both responses
moving pulley up and down are tested using
sequence events (test cases).
In hardware testing, scenarios for testing
intelligent design are provided. Pictures of the
results for each case test were taken and
Network 12: Door Open Signal attached to these scenarios as shown in
simulations test cases results.
After T32 start signalling (5 seconds after

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motor stop) it is made sure that the car is still 3.1 Simulation Results
and a signal to the door motor to run and open
the door is made (Q0.3) another timer (T38) is Two major simulation software packages are
set after that signal (that timer defines how used in the test cases results, namely; PLCSIM
long the door will remain open before a signal and SCADA Simulators.
to close the door is made). When the door S7-PLCSIM is a SIMATIC
open signal is high (Q0.3=1), the door closing Engineering tool for simulating any program
signal is reset (Q0.4=0) to ensure that the two implementation in Siemens STEP-7
signals are not sent simultaneously causing environment. S7-PLCSIM can execute and test
serious design and operation errors. any STEP 7 user program in a simulated
programmable logic controller (PLC).
Similarly, InTouch Wonderware
SCADA software is a Schneider Electric
product, a component of Wonderware Factory
Suite which can create powerful, full-featured
applications that exploit the key features of
Network 13: Door Close Signal
Microsoft Windows including ActiveX
If the timer defining the time period during controls, OLE, graphics, networking and many
which the door should remain open start more applications.
signalling (10 seconds after the door open
3.1.1 PLCSIM Simulation Results
signal was set high) AND if the door open
button was not pressed (I2.0=0) OR if the door
At the start of the simulation module and the
close button was pushed (I2.1) even before the
Ladder programme run mode, the following
10 seconds specified are over, the door close
figure depicts the overview.
signal is sent to the door motor to start running
on the opposite direction and close the car's
door. Consequently, setting the door opening
signal resets the door close signal and
conversely, setting the door close signal resets
the door open signal.

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Figure 5 Initial overview at Start up

3.1.2 Test Case 1: Elevator at Floor 1

From figure 6 below, the ladder configuration
shows the Floor 1 memory location is “SET”.

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Also from the PLCSIM module, the memory Figure 6 Elevator at Floor 1
bit M0.0 and M0.5 confirmed that the elevator
is at floor 1 and the last visit floor is floor 1 The car is at first floor and the output to the 7-
respectively. segment is set to drive it to show decimal
number [1] equivalent of [0001] binary. The
output array shows that only Q1.0 is “high”
and Q0.5, Q0.6, Q0.7 set “low”. The Floor 1
BCD-7 Segment Display is shown in figure 6
above.

3.1.3 Test Case 2: Moving from Floor 1 to

Floor 2
While at the first floor, a call to the second
floor occurred, which makes 2nd floor call
input to be set high (M0.1 = SET), as shown in
figure 7.

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3.1.4 Test Case 3: Moving from Floor 2 to
Floor 3
While at the second floor, a call to the third
floor occurred, which makes 3rd floor call
input to be set high (M0.2 = SET) as shown in
figure 8.

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Figure 7 Floor 2 Call

The car is at second floor and the output to the

7-segment is set to drive it to show decimal
number [2] equivalent of [0010] binary. The
output array shows that only Q0.7 is “high”
and Q0.5, Q0.6, Q1.0 set “low”. The Floor 2
BCD-7 Segment Display is shown in figure 7
above.

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Figure 8: Floor 3 Call

The car is at third floor and the output to the 7-

segment is set to drive it to show decimal
number (3) equivalent of [0011] binary. The
output array shows that Q0.7, Q1.0 set “high”
and Q0.5, Q0.6, set “low”. The Floor 3 BCD-7
Segment Display is shown in figure 8 above.

3.1.5 Test Case 4: Moving from Floor 3 to

Floor 4
While at the third floor, a call to the fourth
floor occurred, which makes 4th floor call

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input to be set high (M0.3 = SET) as shown in Figure 9: Floor 4 Call
figure 9.
The car is at fourth floor and the output to the
7-segment is set to drive it to show decimal
number (4) equivalent of [0100] binary. The
output array shows that only Q0.6, set “high”
and Q0.5, Q0.6, Q1.0 set “low”. The Floor 4
BCD-7 Segment Display is shown in figure 9
above.

However, a lot of other simulations can be

carried out depending on the scenario to be
implemented.

3.2 Creating Window Script for SCADA

Simulation
The simulation of the design was best done by
creating window application script. The scripts
were created from the Ladder Network
described in sub-section 2.8 above.
The window scripts developed are divided into
two parts: the “on show” and the “while
showing”. The “on show” part is necessary to
give the initialization condition while the
“while showing” part implements the flow of
the network.
The following window reports were generated
for the “on show” and “while showing”.

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3.3 SCADA SIMULATION RESULTS
The PLC operation was first tested with the
PLSIM software in the SIMATIC manager as
described in sub section 3.1.1. The Network
Logic parameters are now translated to the
scripts programming in InTouch Wonderware.
The following figure shows simulation layout
and results.

IJSER Figure 10 WindowMaker Design layout

Figure 11 Simulation Start up Runtime Layout

3.3.1 Elevator Simulation status at each
floor
The figures below show the status of the
elevator at each floor. When the elevator is at
any of the floors 1 to 4, the door is opened and
remained opened for the set time (10s in this
simulation). While the door remained opened,
the motor stop signal is “set” and the door
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animation signal is “set”. This is a safety Figure 14 Elevator at floor 3
measure to make sure the elevator is not set to
move while the door is opened. Therefore, at
any floor when the door is opened or opening,
the motor pulley up and down are set at “0”
while the motor stop and door animation
signals are set at “1”.

Figure 15 Elevator at floor 4

3.3.2 Elevator upward call to floors

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Figure 12 Elevator at floor 1 When a call is initiated from a lower floor to
the floor above it, as the elevator is moving up,
the pulley up motor signal is set “high” while
the pulley down motor, motor stop and door
animation signals are set to “0”.

Figure 13 Elevator at floor 2

Figure 16 Elevator call from floor 1 to 2

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Figure 17 Elevator call from floor 2 to 3

Figure 20 Elevator call from floor 3 to 2

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Figure 18 Elevator call from floor 3 to 4
3.3.3 Elevator downward call to floors
Figure 21 Elevator call from floor 2 to 1

When a call is initiated from a higher floor to

any floor below it, as the elevator is moving 4 CONCLUSION
down, the pulley down motor signal is set
“high” while the pulley up motor, motor stop This paper describes implementation for four
and door animation signals are set to “0”. floors elevator with SCADA system using S7-
200 PLC. Also, sensors, pushbuttons, actuators
connection and their configuration at different
floors are effectively incorporated into the
ladder logic network to implement the design
simulation. The developed ladder logic has
been implemented by Ladder diagram
programming. The required inputs and outputs
of elevator for moving upward and reverse,
door opening and closing, and motors
operation have been included in the logic and
interpreted effectively through the simulation
methods (PLCSIM and SCADA)
implemented.

Figure 19 Elevator call from floor 4 to 3

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