Design of Semi-automatic Slotter Machine using PLC

Tejas Patel1, Saurin Sheth3 Bhavin S. Modi2, Purvi Chauhan4

1,3 2
Mechatronics Engineering Department Mechanical Engineering Department
4
G. H. Patel College of Engineering and Technology Production Engineering Department
Vallabh Vidyanagar, Anand Dist., Gujarat 388120, INDIA B.V.M. Engineering College
Vallabh Vidyanagar, Anand Dist., Gujarat 388120, INDIA
[email protected]

Abstract—Now-a-days automation is prime requirement in conversion

industry. Hydraulic system, PLC, controller are key components Controllable Possible with solenoid & Controllable high force
of any automation. Machining attributes a major channel of force DC
Motors Complicated by
finish goods. CNC turning centres, VMC and CNC grinding are need for cooling
available in the market but a retro fitting of Slotter machine is Points to note Danger from electric shock Leakage dangerous and
prime requirement as it is not readily available. So here attempt Unsightly. Fire hazard
is to made to semi automate the Slotter machine using PLC and
hydraulic system. B. Introduction of Programmable Logic Controller
Index Terms—Slotter machine, hydraulic system, PLC and A programmable logic controller (PLC) is a special form of
Automation. microprocessor based controller that uses a programmable
I. INTRODUCTION memory to store instructions and to implement functions such
as logic, sequencing, timing, counting and arithmetic in order
Hydraulics is by far the simplest method to transmit energy to control machines and processes and are designed to be
to do work. It is considerably more precise in controlling operated by engineers with perhaps a limited knowledge of
energy and exhibits a broader adjustability range than either computers and computing languages. They are not designed so
electrical or mechanical methods. A hydraulic system using oil that only computer programmers can set up or change the
is governed by the basic physical law of fluid flow as programs. Thus, the designers of the PLC have pre-
developed by the great scientist Blaise Pascal (1648). This law programmed it so that the control program can be entered using
is known as “Pascal’s law”. The industrial hydraulic system is a simple, rather intuitive, form of language. The term logic is
a power transmission system using oil to carry the power. To used because programming is primarily concerned with
design and apply hydraulics efficiently, a clear understanding implementing logic and switching operations, e.g. if A or B
of energy, work, and power is necessary [1]. The inputs and occurs switch on C, if A and B occurs switch on D. Input
outputs of any power and control system including the devices, e.g. sensors such as switches, and output devices in the
hydraulic system are mechanical such as a rotating shaft or system being controlled, e.g. motors, valves, etc., are connected
reciprocating plunger. An added advantage is that this system to the PLC. The operator then enters a sequence of instructions,
is easily adoptable to a variety of energy forms and the signals i.e. a program, into the memory of the PLC. The controller then
may be initiated by electrical, chemical, manual, optical, monitors the inputs and outputs according to this program and
electronic/digital or acoustic means. Hand levers, plungers, carries out the control rules for which it has been programmed.
springs, rollers and strikers, solenoids and torque motors are
common examples of control inputs, while the output may be
the movement of a piston rod or the turning of a shaft [2].
A. Comparisons of electrical and hydraulic systems

TABLE I. COMPARISONS OF ELECTRICAL AND HYDRAULIC SYSTEMS

Electrical Hydraulic
Energy source Usually from outside Electric motor or diesel
supplier driven
Energy storage Limited (batteries) Limited(accumulator)
Distribution Excellent, with minimal Limited basically a Fig. 1. A programmable logic controller.
system loss local facility
Energy cost Lowest Medium PLCs are similar to computers but whereas computers are
Rotary AC & DC motors. Good Low speed. Good optimized for calculation and display tasks, PLCs are
actuators control on DC motors. AC control. Can be stalled
motors cheap optimized for control tasks and the industrial environment.
Linear actuator Short motion via solenoid. Cylinders. Very high Thus PLCs are:
Otherwise via mechanical force
1 Rugged and designed to withstand vibrations, temperature, E. Flow Control Valve
humidity and noise. The speed of hydraulic actuator by varying the port opening
2 Have interfacing for inputs and outputs already inside the of the flow control valve. This valve is basically a flow control
controller. valve which regulates the fluid flow by enlarging or reducing
3 Are easily programmed and have an easily understood the port area while the oil is passing through the passage. Thus
programming language which is primarily concerned with continuous step less control of speed of a cylinder or a
logic and switching operations. hydraulic motor is possible with such a valve [3].
II. COMPONENTS USED IN HYDRAULIC SYSTEM F. Proximity Sensor
A proximity sensor is a sensor able to detect the presence of
A. Hydraulic reservoirs
nearby objects without any physical contact. A proximity
A hydraulic system is closed, and the oil used is stored in a sensor often emits an electromagnetic field or a beam
tank or reservoir to which it is returned after use. Although of electromagnetic radiation (infrared, for instance), and looks
probably the most mundane part of the system, the design and for changes in the field or return signal. The object being
maintenance of the reservoir is of paramount importance for sensed is often referred to as the proximity sensor's target.
reliable operation. The volume of fluid in a tank varies Different proximity sensor targets demand different sensors.
according to temperature and the state of the actuators in the For example, a capacitive photoelectric sensor might be
system, being minimum at low temperature with all cylinders suitable for a plastic target; an inductive proximity sensor
extended, and maximum at high temperature with all cylinders always requires a metal target. Proximity sensors can have a
retracted. Normally the tank volume is set at the larger of four high reliability and long functional life because of the absence
times the pump draw per minute or twice the external system of mechanical parts and lack of physical contact between
volume. A substantial space must be provided above the fluid sensor and the sensed object [4].
surface to allow for expansion and to prevent any froth on the
surface from spilling out. The tank also serves as a heat G. Programmable Logic Controller
exchanger, allowing fluid heat to be removed. Typically a PLC system has the basic functional
components of processor unit, memory, power supply unit,
B. Filters
input/output interface section communications interface and the
Dirt in a hydraulic system causes sticking valves, failure of programming device. Fig. 2. shows the basic arrangement.
seals and premature wear. Even particles of dirt as small as
20/x can cause damage, (1 micron is one millionth of a metre;
the naked eye is just able to resolve 40/x). Filters are used to
prevent dirt entering the vulnerable parts of the system, and are
generally specified in microns or meshes per linear inch (sieve
number).
C. Directional Control Valves
Hydraulic systems require control valves to direct and
regulate the flow of fluid from pump to the various load
devices. Two types of construction are generally used for
common direction control valves, 1. Seat valve or poppet
valve, 2. Spool valve or sliding valve Fig. 2. The PLC System.
Directional control valves are actuated by various
techniques like manually, mechanically, hydraulically, The processor unit or central processing unit (CPU) is the
pneumatically, electrically. unit containing the microprocessor and this interprets the input
signals and carries out the control actions, according to the
D. Hydraulic Actuators program stored in its memory, communicating the decisions as
Various types of actuators are used in hydraulic systems, action signals to the outputs.
e.g. hydraulic cylinders, motors, etc. A cylinder is device The power supply unit is needed to convert the mains A.C.
which converts fluid power into linear mechanical force and voltage to the low D.C. voltage (5 V) necessary for the
motion. It usually consists of a movable element such as a processor and the circuits in the input and output interface
piston and piston rod, plunger or ram operating within a modules.
cylinder bore. Functionally cylinders are classified as: Single The programming device is used to enter the required
acting cylinders and Double acting cylinders. In contrast to a program into the memory of the processor. The program is
cylinder hydraulic motor provides rotational motion is used in developed in the device and then transferred to the memory
a hydraulic system for a variety of applications where rotary unit of the PLC.
movement is the need. Hydraulic motors generally may be: The memory unit is where the program is stored that is to
Uni-directional, or Bi-directional. be used for the control actions to be exercised by the
microprocessor and data stored from the input for processing B. PLC Programming
and for the output for outputting.
The input and output sections are where the processor
receives information from external devices and communicates
information to external devices. The inputs might thus be from
switches with the automatic drill, or other sensors such as
photo-electric cells, as in the counter mechanism temperature
sensors, or flow sensors, etc. The outputs might be to motor
starter coils, solenoid valves, etc. Input and output devices can
be classified as giving signals which are discrete, digital or
analogue [5,6].
III. HYDRAULIC SYSTEM DESIGN FOR SLOTTER MACHINE

A. Hydraulic Circuit

Fig. 4. PLC programming.

C. Working
Above hydraulic circuit is controlled by PLC. In this
hydraulic circuit, position of hydraulic cylinder is sensed by
proximity sensor and according to PLC programming solenoid
operated valve take the appropriate action.
IV. CONCLUSION AND FUTURE SCOPE
Hydraulic Slotter Machine controlled by PLC having
following advantages over the conventional Slotter machine.
Positional accuracy of stroke length is achieved.
Variable speed of cutting stroke is achieved.
Step less motion of cutting stroke is achieved.
Power consumption is according to the load.
As a future scope, one can automate the motion of
worktable feed and make the complete automated Slotter
machine.
REFERENCES
[1] Andrew A. Parr, Hydraulics andPneumatics, Elsevier Science &
Technology Books, ISBN: 0750644192, March 1999.
[2] George E. Totten, Handbook Of Hydraulic Fluid Technology,
Marceldekker, inc., ISBN: 0-8247-6022-0.
[3] S. R. Majumdar, Oil Hydraulic Systems Principle and
Maintenance, Tata McGraw-Hill, ISBN-10: 0-07-463748-7
[4] http://en.wikipedia.org/wiki/Proximity_sensor
[5] W. Bolton, Programmable Logic Controller, Elsevier’s Science
& Technology, ISBN: 978-1-85617-751-1
Fig. 3. Hydraulic Circuit. [6] http://staffweb.itsligo.ie/staff/kcollins/PLC/PLCProgramming.p
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