Automation of Casting Industries Using Progra...

Automation of Casting Industries Using Programmable Logic Controller

Author Name : Satyender Sharma, Vivek Kumar

ABSTRACT This project work is divided into two parts. The first part deals with the history and development of Programmable Logic Controllers and its subsequent applications in different industries. In The second part PLC was implemented to control the typical metal casting plant. Automation of many different processes, such as controlling machines or factory assembly lines, is done through the use of small computers called a programmable logic controller (PLC). This is actually a control device that consists of a programmable microprocessor, and is programmed using a specialized computer language. Before, a programmable logic controller would have been programmed in ladder logic, which is similar to a schematic of relay logic. A modern programmable logic controller is usually programmed in any one of several languages, ranging from ladder logic to Basic or C. Typically, the program is written in a development environment on a personal computer (PC), and then is downloaded onto the programmable logic controller directly through a cable connection. The program is stored in the programmable logic controller in non-volatile memory. The programmable logic controller has made a significant contribution to factory automation. Earlier automation systems had to use thousands of individual relays and cam timers, but all of the relays and timers within a factory system can often be replaced with a single programmable logic controller. Today, programmable logic controllers deliver a wide range of functionality, including basic relay control, motion control, process control, and complex networking, as well as being used in Distributed Control Systems. There are several different types of interfaces that are used when people need to interact with the programmable logic controller to configure it or work with it. This may take the form of simple lights or switches or text displays, or for more complex systems, a computer of Web interface on a computer running a Supervisory Control and Data Acquisition (SCADA) system. Programmable logic controllers were first created to serve the automobile industry, and the first programmable logic controller project was developed in 1968 for General Motors to replace hard-wired relay systems with an electronic controller. The casting industries are comes in heavy industries and the operating system is very complex. To avoid the wired relay logic here introduces the PLC which controls the various parameters. Here the initial starting of blower and opening of fuel valves according to the temperature like when temperature is low then open valve in more percent and temperature is high then closing the valve. Weighing scale the installed in holding furnace which hold the liquid which comes from furnace the controlling of this weight first depend upon the temperature rate and the weight of tundish. Tundish also have the weighing scale which control the tilting of holding furnace and opening of the metering pin and the speed of the mill which makes the wire of copper. The casting wheel speed also set according to parameters. The controlling of all process is done in both auto and manual mode.