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“Technological Advancement of Pneumatically Controlled End-Of-Arm-Tool Teaching Apparatus”

ET-494_01Senior Design II

Cris Koutsougeras Advisor: Mohammad Saadeh

Fall 2016

Andrew AllemondW0511221

Mechanical Engineering Technology

ET-494_01 Andrew AllemondSenior Design II W0511221Cris Koutsougeras Fall 2016

Table Of ContentsAbstract…………………………………………………………………………………………....3

Purpose……………………………………………………………………………………….……3

PLC Module……………………………………………………………………………………….3

PLC Overview……………………………………………………………………..……..……..3-4

PLC Application…………………………………………………………………..……..………..4

PLC Application Examples………………………………………………………………………..4

PLC Design…………………………………………………….………………………………..4-5

PLC Mechanical Features…………………………………………………………………………5

Human-Machine Interface…………………………………………………………………...….5-6

Human-Machine Interface Example Pictures…………………………………………...…...….6-7

Research And Testing……………………………………………………………………………..7

Professionalizing Project Work………………...……………………………………………….7-8

Professionalizing Project Work Example Pictures..…………………………...………………….8

Meetings…………………………………………………………………………...………………9

Deliverables…………………………………………………………………….…………………9

Ladder Logic Code………………………………………………………………………………10

Refercenes…………………………………………………………………………………….…11

Abstract: Southeastern Louisiana University

500 Western Ave. Hammond, LA 70402 College of Computer Science and Industrial Technology

Department of Engineering Technology


Upgrade Southeastern Louisiana University Engineering Department’s End Of Arm Tool

to a more industry ready PLC system. Incorporate SCADA and HMI. Professionalize system for

presentation and teaching within the Department class’s. The SCADA Software to be

implemented is Ignition Pro by Inductive Automation, and The HMI to be Implemented is

KTP700 by Siemens.

Purpose:

A key element in the Engineering Technology (ET) program at Southeastern is to be able

to work with industry ready software and projects to better prepare for life after college. Students

in ET program have access to some resources that are available in the electronics lab such as

PLC, actuators, sensors, software, and microcontrollers but a lot are not industry ready or seen in

the engineering society. However, there is a need for industry ready systems that integrate all

these individual components under one control unit. Once completed, this project will deliver

our ET program with an additional source to better formulate our alumni for actual work

situations to prove that Southeastern’s Engineering Department is one of high class and high

work force ready graduates.

PLC Module:

Siemens Simatic S7-1200

PLC Overview:

A PLC has several basic concepts and functional capabilities that make it attractive for

the user. Some of the features are that it has compact controllers for the low to mid-performance

ranges; large-scale integration that is space saving and powerful with exceptional real-time

performance and powerful communication options as well as controllers that are integrated with

PROFINET IO Controller interface for communication between SIMATIC controllers, HMI,

programming device or other automation components. Another feature is that all CPUs can be

used in stand-alone mode, in networks and within distributed structures, with extremely simple

installation, programming, and operations and an integrated web server with standard and user-

specific web pages. Some other appealing features are its data logging functionality for archiving Southeastern Louisiana University

500 Western Ave. Hammond, LA 70402 College of Computer Science and Industrial Technology

Department of Engineering Technology


of data at runtime from the user program; powerful, integrated technology functions such as

counting, measuring, closed-loop control, and motion control. It also contains integrated digital

and analog inputs/outputs, flexible expansion facilities, signal boards for direct use in a

controller, and signal modules for expansion of controllers with input/output channels, including

an Energy Meter module for recording and preparing energy data. Finally, the accessories, e.g.

power supply, switch module, or SIMATIC Memory Card are a plus.

PLC Application:

The SIMATIC S7-1200 is the controller for open-loop and closed-loop control tasks in

mechanical equipment manufacture and plant construction. Due to the compact modular design

with a high performance at the same time, the SIMATIC S7-1200 is suitable for a wide variety of

automation applications. Its range of use extends from the replacement of relays and contactors

up to complex automation tasks in networks and within distributed structures. The S7-1200 also

increasingly opens up areas for which special electronics was previously developed for economic

reasons.

PLC Application Examples:

Some of the ways a PLC are used in everyday applications are placement or conveyor

systems, elevators and escalators, material transportation equipment, metal working and

packaging machines, printing and textile machines, and mixing systems. Some others are

freshwater treatment plants, wastewater treatment plants, external displays, electricity

distribution stations, room temperature control, heating/cooling system control, energy

management, fire protection systems, air conditioning, lighting control, pump control, and

security/access control systems, just to list the most commonly found applications.

PLC Design:

The SIMATIC S7-1200 family consists of the following modules:

-compact controllers with graded performances in different versions as wide-range AC or DC

controllers

Southeastern Louisiana University500 Western Ave. Hammond, LA 70402

College of Computer Science and Industrial Technology Department of Engineering Technology


-signal boards (analog and digital) for low-cost modular controller expansion directly on the

CPU, with retention of the mounting space

-different digital and analog signal modes

-different communication modules and processors

-Ethernet switch with 4 ports for implementation of many different network topologies

-SIWAREX weighing systems terminal module

-PS 1207 stabilized power supply units, line voltage 115/230 V AC, rated voltage 24 V DC

PLC Mechanical Features:

-easy mounting of the modules on a standard DIN rail or in a control panel

-rugged, compact plastic enclosure

-easily accessible connection and control element, protected by front flaps

-removable connection terminals, also for analog or digital expansion modules

Human-Machine-Interface:

HMI, or human-machine interface, is the input-output device through which the human

operator controls the process, and which presents process data to a human operator. HMI usually

is linked to the SCADA system’s database and software programs, to provide trending,

diagnostic data, and management information such as scheduled maintenance procedures,

logistic information, detailed schematics for a particular sensor or machine, and expert-system

troubleshooting guides. The HMI system usually presents the information to the operating

personnel graphically, in the form of a mimic diagram. In this way, the operator can see a

schematic representation of the plant being controlled. For example, a pump connected to a pipe

can be made into a picture that shows the pump is running and at what rate the fluid is being

pumped at any given moment. The operator can choose to let the pump run or to switch it off.

Therefore, the HMI software can show the decrease in the rate of fluid flowing in the pipe in real




time. Mimic diagrams may consist of line graphics and schematic symbols to represent the

process elements, or may consist of digital photographs of the process equipment overlain with

animated symbols. The HMI package for the SCADA system typically includes a drawing

program for the operators or system maintenance personnel use in order to change the way these

points are represented in the interface. These representations can be as simple as an on-screen

traffic light, which can represent the actual traffic light in the field, or as complex as a multi-

projector display representing the position of all of the elevators in a skyscraper or of all the

trains on a specific railway.

Human-Machine-Interface Example Pictures:




Research and Testing:

Testing each element of the EOAT was essential to comprehend the processes of the

machine. Testing included checking wiring for correct input and output, rewiring lasers and

sensors for correct functionality, and testing communication from the PLC and HMI.

Throughout the process, much research was done to understand every module and

process on the system. The datasheets and wiring connection diagrams were compiled in a excel

spreadsheet to serve as a manual for future work on the project or to showcase, operate the

EOAT system. All components and wirings were coded and labeled to easily identify them, and

allow future upgrading or expansion.

Professionalizing Project Work:

Throughout the history of Southeastern Louisiana University’s Engineering Department,

the department has had many opportunities to provide other schools the knowledge and

professionalism that we teach here. It was one of my top priorities to change this previously

worked on project into a clean and professional looking tool for our school to showcase. A few

matters that I tended to was the incomplete wood work done on the machine and frame. Another

aspect I completed was the unpleasant looking wires all over the place. I purchased and install




wire concealers and organized wires in order to make the project a more professionalized piece

of teaching apparatus. Lastly, at the conclusion of this class I will provide my advisor Dr.

Mohammad Saadeh with a USB drive containing all work completed within this project for the

use of possible re work or showcasing of the teaching apparatus.

Professionalizing Project Work Example Pictures:

IN PROGRESS




Meetings:Upon approval of the project by Professor Koutsougeras, the project will then go forward

with weekly meetings with the advisor (Mohammad Saadeh). Deliverables will then be created

in agreement with the advisor in order to secure progress with the project for the semester.

Deliverables:• Reach Out To Previous Students On Project Information (What Was Done Before)

• Research New PLC and SCADA (Siemens / Inductive Automation)

• Prepare For Proposal Presentation (Paper, PowerPoint)

• Create Excel File With Materials List Of All Necessary Modules Needed

• Download All Necessary Software For New PLC And SCADA (Step 7 / Ignition Pro)

• Learn Wiring Diagrams Of Old And New PLC

• Create Excel File With Old And New Wire Codes

• Wire New S7-1200 PLC Module

• Create Excel File With Old And New Input / Output Connections With Labels

• Program New PLC For Desired Sequence

• Learn Human-Machine-Interface Programming

• Program Human-Machine-Interface

• Learn SCADA Software

• Program SCADA

• Integrate SCADA / PLC / Human-Machine-Interface Together

• Organize EOAT for Visual Clean / Professional Project (Wire Ducts, Finish Wood Work,

Enclose PLC Area, Fix Minor Eye Sores, etc.….)

• Provide Southeastern Louisiana University Engineering Technology Department With

Finished Flash Drive Of All Files, Pictures, And Programs For Teaching

• Prepare for Final Presentation (Paper, Flash Drive, Transportation of Machine to

Presentation, PowerPoint, etc…)




Ladder Logic Code:

IN PROGRESS




References:

SIMATIC HMI Panels - Siemens. (n.d.). Retrieved October 9, 2016, from http://www.automation.siemens.com/salesmaterial-as/brochure/en/brochure_panels_en.pdf

Hmi Interface. (n.d.). Retrieved September 23, 2016, from http://www.globalspec.com/Industrial-Directory/hmi_interface

SCADA Security Risks and Concerns. (n.d.). Retrieved November 4, 2016, from http://scadawiz.com/security/risks-and-concerns/

Supervisory Control and Data Acquisition (SCADA) Systems. (n.d.). Retrieved November 13, 2016, from https://scadahacker.com/library/Documents/ICS_Basics/SCADA Basics - NCS TIB 04-1.pdf

Simatic. (n.d.). Retrieved October 27, 2016, from https://de.wikipedia.org/wiki/Simatic

