Machine and Industrial Automation

/Machine and Industrial Automation
Machine and Industrial Automation2018-11-23T11:34:45+00:00

Machine and Industrial Automation

Pressure Booster Pump Control Using Smart Relay Genie-NX


Task

In a water distribution system in large buildings, it is required to operate four pumps in a cyclic manner and maintain the overall water pressure in the pipe for the optimum utilization of water. The water level from both upper and lower tank needs to be monitored to avoid pumps from dry running or over spillage of water.

Solution

A simple solution is to use Smart Relay Genie-Nx from GIC.

Input
  • I1, I2, I3, I4 are the pressure switches for the respective pumps.
  • I5 and I6 for Upper level and Lower level input for monitoring the level.
  • I7, I8, I9, I10 are the inputs for voltage trip indication.
Outputs
  • Q1, Q2, Q3, Q4 are the outputs for the respective pumps.
  • Q5 hooter for trip indication.

In order to protect the pumps from excess running, a ladder logic is developed to maneuver pumps in cyclic manner for load sharing there by increasing the operational redundancy of the system. In order to maintain the pressure of water across all the floors, the pumps are operated based on the input from the pressure switches. Whenever the water level reaches the predefined higher/lower limit pumps will be turned OFF and trip indication will be signaled by hooter to avoid dry running or over spillage of water. The pump will resume its normal operation as soon as the water level reaches to a predefined level set by the customer. The G-soft NX II software designed for Smart Relay Genie-Nx, makes it convenient for the end users to build customized ladder programs for several applications.

Portable Organic Waste Composting Machine Using Mini PLC PL-100, Liquid Level Controller and Temperature Controller


Task

In a portable organic waste composting machine, it is required to monitor and control temperature, moisture level as well as proper mixing of garbage in order to produce the perfect compost manure.

Advantages
  • Supports up to 48 I/O s
  • 250 lines of ladder programming
  • Backlit LCD screen for display & modification of pre-selected parameter of functional blocks, viewing I/O status and programming on the device.
  • PC software for programming, online & offline simulation, documentation and printing
  • 16 soft text messages, Time switches, compare counters, timers, Hour meters, counters and analog functions
  • DST feature available
Solution

Mini PLC PL-100 along with the Temperature controller PR43 and Liquid Level Controller(LLC) from GIC are used in this application. The liquid level of the input garbage is sensed by liquid level controller and the corresponding feedback is provided to the PLC. Based on this input, PLC gives further command to regulate the temperature of heater to control the moisture level of input garbage. To ensure proper and periodic mixing of input garbage the mixer is effectively controlled by PLC for the forward and reverse operation. Interlinking LLC and temperature controller with PLC helps in achieving the highest quality of compost manure.

Advantages
  • Analog voltage and current input/output of 0-10V/4-20mA
  • Multiple Timers, Counters including retentive counters, Hour meters
  • Modbus RTU support
  • Control output: Relay & SSR Drive
Solution

Industrial washing machines are used to wash mechanical parts with the help of petrochemical solution. Normally it is required to initiate the washing process before the worker’s shift timing in order save time and reduce process cycle time. This is achieved by using DC variant of Digital Time Switch Crono. Inbuilt RTC feature helps to automatically control the duration of washing cycle as per the shift timings. 25 on/off programs and 6 years battery reserve makes Crono indispensable for process optimization.

Advantages
  • Delayed on or off switching of groups of loads
  • Fast, reliable and secure protection against tampering
  • Operating cost can be drastically reduced

Garbage Chute Application Using Mini PLC PL-100


Task

In high rise residential buildings, it is required to monitor and control garbage chute in order to avoid multiple handling of the system and to ensure proper segregation of dry and wet waste.

Solution

Typically, in a garbage chute application, there is a possibility of multiple individuals trying to access the garbage chute at the same time. To avoid any accidental damage to the individuals, the Mini PLC PL-100 from GIC is used to effectively monitor and control the access points of garbage chute installed at every floor of the building. Door sensors of the garbage chute at each floor are linked with the PLC and this enables to govern the operation with precise timing and provides access to single user at a time. Depending on the user selection of dry and wet waste the diversion flap at the bottom of the garbage chute is controlled to effectively segregate the waste. The wet, dry and busy conditions are indicated on the display of the garbage chute.

Advantages
  • Analog voltage and current input/output of 0-10V/4-20mA
  • High-speed input/output
  • Multiple Timers, Counters including retentive counters, Hour meters
  • Modbus RTU support
Time Switches

Cold Storage Control Using Digital Time Switch Crono


Task

In the conventional cold storage application, it is required to operate two air conditioner units automatically one after the other in order to distribute load and save energy.

Solution

In order to maintain the temperature in the cold storage, high capacity air conditioners are installed so that the perishable products can be preserved and stored effectively. The digital time switch Crono from GIC is used to automatically switch ON/OFF air conditioner units as per predefined schedule in order to distribute load and save significant amount of energy. This helps to avoid the over usage of air conditioner units thereby reducing maintenance costs.

Advantages
  • Delayed on or off switching for groups of loads
  • Fast, reliable and secure protection against tampering
  • Operating cost can be drastically reduced