2 December 2023
List of latest project topics on PLC

putting in place an automated industrial control system based on PLC and HMI

An automated industrial control system using PLC and HMI (Human-Machine Interface) is a frequent project topic in the field of industrial automation. Below is a summary of the steps required to complete this project:

1. Determine the control requirements

Find out what the automated industrial process requires exactly. This procedure includes identifying the system’s inputs, outputs, sensors, actuators, and other components.

The first stage in developing an automated industrial control system employing a 1766-L32BXB MicroLogix 1400 PLC and HMI is determining the control needs. It entails determining the precise specifications of the industrial process that will be automated. The main phases in defining the control needs are briefly described here:

  • Identify the inputs: Identify the different signals that the system receives from sensors, switches, and other devices. For instance, the inputs to a temperature management system might include temperature sensors, heater or cooler on/off switches, and other relevant signals.
  • Identify the outputs: Determine the system’s necessary outputs, such as the motors, valves, pumps, and other actuators. For instance, the outputs of a conveyor control system can include conveyor motors, jam-detection sensors, and other relevant actuators.
  • Identify the control functions: Determine the precise control operations that the system needs, such as on/off, proportional, PID, and other related operations. For instance, the control function of a level control system can entail maintaining a certain liquid level in a tank by regulating the pump’s flow rate.
  • Identify the safety requirements: Make a list of any safety standards that the control system has to meet, such as emergency stop buttons, interlocks, and other relevant safety features. Safety elements in a robotic arm control system, for instance, may include emergency stop buttons and sensors for detecting human presence.
  • Identify the communication requirements: Determine the system’s communication needs, such as if the PLC and HMI or different PLCs in a distributed control system need to communicate. For instance, in a smart home automation system, the communication needs can include employing a wireless protocol like Wi-Fi or Bluetooth to link the PLC and HMI to the internet.

2. Select the PLC:

Based on the needs of the system, a PLC should be chosen. Three well-known PLC producers are Siemens, Allen-Bradley, and Mitsubishi Electric.

  • Performance: Given that the Allen Bradley PLC’s performance affects how quickly and effectively the control system operates, it is essential to take this into account. Processing speed, memory size, and connection speed are a few variables that affect how well the PLC performs.
  • Input/output (I/O) requirements: The number and kind of I/O modules the PLC needs will depend on the system’s I/O requirements. The numerous sensors and actuators in the system are linked to the PLC by the I/O modules.
  • Programming languages: The flexibility and simplicity of programming the control system are determined by the programming languages that the PLC supports. Structured text (ST), ladder logic, and function block diagram (FBD) are some common programming languages used in PLCs.
  • Expandability: A crucial factor to take into account is the system’s future expansion potential, particularly if it is anticipated that the system may expand or undergo other changes. The PLC has to have enough expansion slots so that new I/O modules, communication modules, or other accessories may be added.
  • Compatibility with HMI software: The HMI software that is used to create the control system’s user interface and the PLC should work together seamlessly. This makes sure that the PLC and HMI can communicate effectively.
  • Reliability and support: It’s also important to take into account the provider or manufacturer of the PLC’s dependability and accessibility of technical help. This guarantees that any PLC problems may be fixed effectively and fast.

Also Read :- Rockwell Automation 1766-L32BXBA MicroLogix 1400 PLC

3. Design the PLC program:

Create the PLC programme (ST) using ladder logic, function block diagrams (FBD), or structured text. The programme should contain the control logic for the inputs, outputs, alarms, interlocks, and other control operations.

4. Connect the PLC to the sensors and actuators:

Connect the sensors and actuators to the PLC using the appropriate wiring and cable.

5. Design the HMI:

Create the HMI displays using programmes like FactoryTalk View, Wonderware InTouch, or WinCC. The HMI displays should make it simple for operators to monitor and manage the system.

6. Connect the HMI to the PLC:

Connect the HMI to the PLC using an appropriate communication protocol, such as Ethernet/IP, Modbus TCP, or OPC-UA.

7. Test the system:

Verify the system’s operation and adherence to the requirements. This includes testing the PLC programme, HMI displays, and PLC and HMI connectivity from Rockwell Automation.

8. Deploy the system:

Install the system in a commercial environment and instruct the operators on how to use the HMI and interact with the system.

Overall, the implementation of a PLC and HMI-based automated industrial control system necessitates both hardware and software expertise. Additionally, a solid grasp of industrial control systems and the particular needs of the automated process are needed.

Asteam Techno Solutions Pvt. Ltd. has boasts over 10 years of experience in the industrial sector, founded in India and then became one of the best industrial automation parts supplier in India as well as globally. We provide automation solutions with reputed brands including Allen Bradley, Mitsubishi, Phoenix Contact, Siemens, Schneider, Moxa, VIPA and more.

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