Final Exam 2016 Phase III Change Notice

Final Exam 2016phase Iii Change Noticeby Now You Should Have Been U

Develop a comprehensive final program using PLCs, HMI, and ladder logic based on specifications including creating main, diagnostics, and alarm screens, simulating tank levels and fire conditions, and configuring I/O tags and internal bits, ensuring proper functionality and coordination between hardware and software components.

Paper For Above instruction

The final exam project for the 2016 phase III course centers on designing and programming a PLC-based control system integrated with an HMI interface to simulate real-world industrial processes. This comprehensive project involves creating multiple HMI screens, implementing ladder logic for tank level management, emergency alarms, and diagnostics, as well as configuring input/output tags and internal memory bits. The goal is to develop a robust, functional, and user-friendly control system that demonstrates proficiency in automation programming, HMI design, and system troubleshooting.

Initially, students are instructed to develop a Main Program Screen (F1) mimicking the PLC trainer's pushbutton (PBs) and lights. This screen must accurately reflect the layout, color, and labeling of the physical controls, providing intuitive interaction for operators. The design involves representing nine items—PBs and switches—and ensuring they visually match their physical counterparts. Importantly, the control of these physical inputs cannot be directly activated via the HMI; hence, internal memory bits (M-bits) starting from address %M5.0 are used to mirror each hard-wired input, allowing for simulation and testing within the HMI environment.

Next, a Diagnostics Screen (F2) demands implementing a simulation for testing eight outputs (Q0.0 to Q0.7). Internal M-bits, starting at %M6.0, are used to emulate each output’s state over a 5-second test cycle. The software should visually display eight corresponding indicator lights, turning on when each simulated output is active, helping verify the correct operation of the control logic. Proper labeling, such as “Diagnostics – E-stop Q1,” enhances clarity. This testing feature facilitates troubleshooting and validation of the output control logic before deployment in real hardware.

The third display, an Alarm Screen (F3), focuses on monitoring eight input conditions that could activate alarms. Similar to the outputs, internal memory bits starting from %M7.0 are used for simulation. Indicators on the HMI should properly reflect when an input triggers an alarm, turning on separate lights and a prominent red alarm indicator when necessary. This functionality ensures operators are promptly notified of hazardous or abnormal operating conditions, critical for safety and process integrity.

In addition to the HMI and interface development, students are tasked with programming ladder logic to replicate the physical systems more realistically. This involves the creation of simulations for tank level management, fire alarm conditions, and water flow control within the tanks. Two input blocks will be established to manage North and South tank levels, accepting pressure or level readings, and controlling solenoids based on these readings. The logic must simulate water inflow at a rate of 1 foot every 5 seconds when the level drops below 22 feet, and turn off when the level reaches or exceeds 28 feet. It must also prevent overfilling beyond 31 feet, accounting for an overflow tube.

Furthermore, a dedicated input block for fire alarm conditions is to be developed, accepting values 1, 2, or 3, indicating the number of DWP (District Water Pump) units to activate. The logic needs to ensure both tank solenoids turn on during fire conditions and that the appropriate number of DWP units increase VFD speeds to meet water demand. This dynamic response simulates a real fire-fighting setup, where multiple pumps coordinate based on system demand.

Students are also encouraged to familiarize themselves with HMI programming, especially connecting HMI inputs/outputs to the PLC program with appropriate tags and internal bits. This understanding is essential for creating intuitive interfaces, enabling operators to set tank levels, activate emergency conditions, and view system diagnostics in real-time. The project is planned over a timeline of approximately two weeks for the HMI programming component, with ongoing support and questions addressed during class sessions.

Finally, the comprehensive program must be assembled with proper configuration of I/O tags, ensuring all physical inputs and outputs are correctly mapped to their logical counterparts. The configuration involves assigning specific address tags to for example, I0.0 for the E-stop, and Q0.0 for the E-stop output, as outlined in the project instructions. Internal bits are also to be utilized within Siemens TIA Portal for controlling simulation states and internal logic (such as %M bits for diagnostics and input simulation).

In conclusion, this project demands a multi-faceted approach blending ladder logic programming, HMI design, system simulation, and configuration management. Students must demonstrate the ability to integrate hardware and software, provide detailed visual feedback through HMI screens, and ensure safety and efficiency in simulated industrial processes. This comprehensive experience prepares students for real-world automation system design, emphasizing troubleshooting, system validation, and user-centered interface development.

References

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• LabVIEW and PLC Programming Tutorials. (2020). National Instruments. Retrieved from https://www.ni.com
• Siemens AG. (2020). SIMATIC STEP 7 and TIA Portal Programming Environment. Siemens Documentation.
• Franklin, G., & Powell, W. (2017). Mechatronics: Principles and Applications. Pearson.
• Wieland, T. (2018). Industrial Automation: Hands on. Automation Press.
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• International Society of Automation (ISA). (2022). Best Practices in HMI Design.
• Schwab, R. (2019). PLC Programming Methodology. Elsevier.