PLC based automated coal crushing and conveyor system SUBMITTED BY S.SIVASUBRAMANIAN(11IC036) M.S.SURYA PRAKASH(11IC039) G.MANIBALAN(11IC015) GUIDED BY MR.J.KUMERESAN ,M.E. (ASST. PROFESSOR) DEPARTMENT OF ICE

ABSTRACT Our project is to design an automated coal crushing and conveyor system based on programmable logic controller. The crusher will crush the large blocks of coal into small granular particles. The crushed coal transferred to the conveyor belt with pneumatic cylinder. The coal gets filled in a container on other end of the conveyor.

EXISTING METHOD manual work of coal handling process

NEED FOR THE PROJECT Power generation will be increased. Automatic controllable. Manual roller type coal transportation is eliminated. The measurement of coal transported is done automatically by this system. The replacement of simple relay control system with old style mechanical sensing devices.

PROPOSED METHOD

programmable logic controller   A Programmable Logic controller, PLC or Programmable Controller is a digital computer used for automation of electromechanical processes. The Programmable Logic Controller or PLC is an industrial computer designed to run specific tasks quickly and efficiently. PLC is an user friendly microprocessor based specialized computer that carries out control functions of many types and levels of complexity.

Architecture of PLC

Coal crusher

Conveyor belt

BLOCK DIAGRAM

SYSTEM MODEL

Hardware and software Programmable logic controller Coal crusher Conveyor belt IR sensor and proximity sensor PLC ladder logic

DC MOTOR

DC MOTOR OPERATION The operation of DC motor is based on principle of electromagnetism. A current-carrying conductor generates a magnetic field; when placed in an external magnetic field, it will experience a force proportional to the current in the conductor, and to the strength of the external magnetic field. The internal configuration of a DC motor is designed to harness the magnetic interaction between a current-carrying conductor and an external magnetic field to generate rotational motion.

PNEUMATIC CYLINDER As air is pushed into the connection, the plunger begins to move and compress the spring. Exhaust air exits out the exhaust hole on the other end. When air is released, it exits out the connection, and air is sucked into the exhaust hole as the spring pushes the plunger back to its resting position.

IR SENSOR A Infra Red sensor (IR sensor) is an electronic device that measures infrared (IR) light radiating from objects in its field of view. Infrared transmitter is one type of LED which emits infrared rays generally called as IR Transmitter. Similarly IR Receiver is used to receive the IR rays transmitted by the IR transmitter. One important point is both IR transmitter and receiver should be placed straight line to each other. The transmitted signal is given to IR transmitter whenever the signal is high, the IR transmitter LED is conducting it passes the IR rays to the receiver. When receiver receives the signal from the transmitter it resistance value is low. It resistance value become high when the signal was cut.

RELAY The relay circuit is designed to control the load. The load may be motor or any other load. The load is turned ON and OFF through relay. The relay ON and OFF is controlled by the pair of switching transistors (BC 547).

LADDER LOGIC DIAGRAM

SWITCH FOR THE CONVEYOR AND MOTOR

PNEUMATIC OPERATION WITH TIMER

MOTOR REVERSE OPERATION

FUNCTION OF LADDER DIAGRAM The conveyor belt and reverse motion (or) downwards of the crusher starts with switch (SW_MAIN). The reverse motion of the crusher stops with the lower proximity sensor limit (LWR LMT SET) which crushes the coal and moves upwards (or) forward to reach the upper proximity sensor limit (UPR LMT SET). When the crusher reaches the upper proximity sensor limit (UPR LMT SET) it will start the operation of pneumatic cylinder (UPR LMT PSTN) with 3 sec timer (T1.T2.T3). The pneumatic cylinder will transfer the crushed coal to the conveyor belt and come to its initial position at the end of the timer count (3 sec). The process of crusher reverse and forward motion with the pneumatic cylinder operation repeats until the PLC gets signal from the IR sensor (IR_SR).

OPERATION OF LADDER DIAGRAM OPERATION 1: The conveyor belt and crusher starts with the main switch. OPERATION 2: The reverse motion of the crusher with the upper proximity limit sensor. OPERATION 3: The crushing process of the coal. OPERATION 4: The forward motion of the crusher with the lower proximity limit sensor. OPERATION 5: The pneumatic cylinder get started. OPERATION 6: The coal transfer to the conveyor with the pneumatic cylinder. OPERATION 7: The process repeats until signal from the IR sensor.

ELECTRICAL BOARD

HARDWARE SNAPSHOT

ABB TYPE PROGRAMMABLE LOGIC CONTROLLER

ADVANTAGE Fast and time saving with greatest flexibility Easy to implement and handle. Pollution to the human living will be reduced due to automation. Higher efficiency of handling coal compared to manual method. Power generation will be increased compared to existing method. The system does not require any complicated sensors.

CONCLUSION Thus the system provides automation of coal crushing and conveyor process with the elimination of human working hazards in vehicle crusher and transportation. It reduces the labour cost and PLC can be used for future enhancement of industrial automation.

THANK YOU

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