Implementation of Automatic Color Mixing and Filling Using PLC & SCADA
Implementation of Automatic Color Mixing and Filling Using PLC & SCADA
Implementation of Automatic Color Mixing and Filling Using PLC & SCADA
Abstract: The objective of this paper is to design, the colors in different proportion and fill the bottle till a
develop and monitor “Automatic Color Mixing and desired level without wastage of the liquid. Ladder logic is
Filling Using PLC and SCADA”. A modern used to perform the sequence of operation. The system is
programmable logic controller deliver a wide range of controlled by a Allen Bradley Micrologix 1400 Series-B
functionality, including basic relay control, motion PLC which operates on 24V DC and is a compact PLC
control, process control, and complex networking, as well which has a fixed number of inputs and outputs i.e., 32
as being used in Distributed Control Systems. There are number of digital input/output ports and 6 number of
several different types of interfaces that are used when analog input/output ports. In addition to this, the use of
people need to interact with the programmable logic SCADA has also been implemented for the monitoring of
controller to configure it or work with it. the entire system.
In this application, going to mix the color in different
proportion and fill in a bottle using PLC (Programmable 2. METHODOLOGY
Logic Controller) and SCADA (Supervisory Control and
Data Acquisition). Here Allen Bradley Micrologix 1400x There are three containers, first container contains color 1
PLC is used, which acts as the heart of the system. The liquid, second container contains color 2 liquid with the
system sequence of operation is designed by ladder respective solenoid valve connected on it, and middle
diagram. Several electronics and electric devices that container is mixing and filling container. Mixing container
usually be controlled and operated by the PLC such as a connected with a solenoid valve and a level sensor to sense
submersible motor pump, conveyor belt, solenoid valve, the water level in it.
When the level sensor moves from NO contact to NC
relays etc. This system is applicable in color mixing plant,
contact the conveyor belt (i.e. DC Motor) starts rotating.
milk industries, chemicals, foods, mineral water and
Afterwards the bottle is placed on the conveyor then
many more manufacturing, processing and packaging
proximity sensor 1 senses the bottle and conveyor belt
industries. A prototype has been developed to illustrate
the application. stops below the solenoid valve 3.Then there will be delay
Keywords: Allen Bradley, Automation, Ladder Logic, of 5 seconds, after this solenoid valve open and starts
PLC, SCADA. filling the bottle for 15 seconds, after 2 second of delay
filled bottle will move forward on conveyor system till the
proximity sensor 2 senses the bottle. After this the process
1. INTRODUCTION continues till the stop switch is not pressed.
Automation is used to reduce the human work and helps
in increasing the production. PLC plays an 3. PROPOSED MODEL
important role in the world of automation industry. It acts
as major function in the automation field which tends to The whole system is divided in two important parts
reduce the complexity, increases safety and cost efficient. hardware and software
It requires continuous monitoring and inspection at 3.1 Hardware Description
frequent intervals. There are possibilities of errors in
Number equations consecutively with equation numbers in
parameter measuring, human intervention at various
Allen Bradley Micrologix 1400 Series-B used for
stages and also the lack of advance features. Thus this
controlling the inputs and outputs. The model number of
paper takes a sincere attempt to explain the benefits to the
PLC is 1766-L32BXBA. The PLC controls the input and
companies by making process automated. In order to
output according to the program. Input supply to the PLC
automate a plant and minimize human intervention, there is is given through a SMPS as this is the compact type of
a need to develop a system that monitors the plant and PLC. The rating of the SMPS is 24V DC, 5Amp. Various
helps to reduce the errors caused by humans. proximity sensors have been used for the positioning of the
bottle. A DC motor is used for the conveyor system. The
PLC is the main part of the system which makes the rating of the DC motor is 24V for high torque. Toggle
whole process simple, flexible and accurate. A color switch and push buttons are used which acts as the input to
mixing and filling system with PLC allows the user to mix the PLC. Solenoid valve is used for the filling process of
7 SCADA
SCADA stands for “Supervisory Control and Data
Acquisition. Previously without SCADA an industrial
process was entirely controlled by PLC, CNC, PID &
micro controllers program. These programs were either Figure-8 SCADA view during the process
written in assembly language or relay logic without any
monitoring. Using SCADA we can visualize the graphical 8 PROTOTYPE OF AUTOMATIC COLOR MIXING
view of the entire process and also control from the remote
place or control room. [2] AND FILLING USING PLC & SCADA
Figure-9 shows the prototype of the automatic color
Features of typical SCADA software include, mixing and filling using PLC & SCADA.
Dynamic process graphic
Real-time and Historical trending
AUTHORS
Mrs Hinal Shah, currently working as
Assistant Professor in the Department of
Electrical Engineering in Indus University. She
has 8 years of teaching experience.