The project is designed to switch industrial loads using a user programmable logic control device for sequential operation. This operation is generally used for repetitive nature of work. Programmable logic controllers used in industrial applications are very expensive for simple operations like sequential switching of loads. The development of this application requires the configuration of the program through input switches.
In industries, there are many tasks are carried out which requires some repeated operation in various orders and time intervals. For example, certain loads need to be switched ON/OFF in specific time intervals. In set mode, through timers, the machinery works based on input time set by the user where as in auto mode it works on default time settings and finally in the manual mode it functions while respective switches are pressed depending on the user’s need and flexibility. All the modes and status of loads are displayed on an LCD.
The analysis carried out in this project highlights the concepts, working, advantages and practical applications of programmable logic controllers, along with a comparison with other control systems for industrial automation in repetitive nature of work. This operation is generally used for repetitive nature of work the main objective of the project is to design of any load using embedded system based microcontroller concept. It uses microcontroller from the 8051 family, which is of 8-bit. The development of this application requires the configuration of microcontroller architecture – that is, the selection of the machines, and writing debugging of the application program. In this project, the clock plays an important role, wherein it is used in these modes: the set mode, auto mode and manual mode for controlling different machines. In the set mode – through the inbuilt digital clock – the machinery runs based on the ‘On’ or ‘Off’ and on time, whereas in an auto mode, it runs through default settings; and, finally in the manual mode, the real-time systems used extensively in the industrial control applications can run depending on the user’s need and flexibility.
The power supply consists of a step- down transformer 230/12V, which steps down the voltage to 12V AC. This is converted to DC using a Bridge rectifier. The ripples are removed using a capacitive filter, and it is then regulated to +5V using a voltage regulator 7805, which is required for the operation of the microcontroller and other components.