Industrial and Automation System 2016

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Our Goals

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The final target is to design a PLC controller in order to:

● Perform a simulation of a control of a traffic light road system;

● Learn the use of Twido PLC model TWDLCAA16DRF;

● Learn the use of TwidoSoft software.

History: a traffic light system

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Programmable Logic Controller (PLC)

Characteristics:

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Programmable Logic Controller (PLC)

Characteristics(2):

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PLC: Block Diagram

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Twido PLC: Power Supply

● The Phase and Neutral references

have been connected to the

electrical system from 100 to 240

Vac.

● The ground connection in general

will not be connected to anything

because the PLC itself already has

an electrical reference.

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Twido PLC: Input

Three distinct and separate

regions:

● The first two contacts, DC OUT,

provide an internal power supply

of +24V at 150 mA and another

one of 0 Vcc, used to power the

inputs or outputs;

● The third contact, DC IN, is used

to supply the inputs and

determine the Positive or

Negative logic;

● The remaining 9 contacts (0 to 8)

connect various inputs device;

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Twido PLC: Output

Three distinct and separate regions:

RED: Locate the contacts of outputs 0 to

3;

GREEN: Locate the output contacts 4

and 5;

BLUE: Locate the output pin 6.

Ry COM0, 1 and 2 are used, by connecting

a power supply, to power corresponding

outputs.

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Twido PLC: at the top

Status LEDs :

● Input (0 to 8)

● Output (0 to 6)

● Run

● Power

● Error

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Twido PLC: Interfacing

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TwidoSoft: Main window

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TwidoSoft: Ladder Viewer window

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TwidoSoft: Ladder Editor window

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Traffic Lights Control System(TLCS) prototype

Thanks the support of

Fablab Messina we created

a prototype of TLCS that

we used in combination

with the PLC.

This prototype allow us to

give an output to the logic

implemented by using the

PLC.

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Main Activities

(1) PCB (printed circuit board): design and creation

(2) Traffic Lights: design and creation

(3) Packaging: design and creation

(4) Final Prototype: assembling and testing

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(1)PCB (printed circuit board): design and creation

PCB design with KiCad-EDA

convert Kikad-EDA to TIFF

setting laser cut software tool

painting of the copper plate

laser cutting of the painted copper plate

engraving the copper plate with the FeCI3

cleaning the copper plate with a solvent

making holes on the final PCB

component soldering on the final PCB

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PCB design with KiCad-EDA

KiCad-EDA (http://kicad-pcb.org/ ), a cross platform and open source electronics design automation suite

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convert Kikad-EDA to TIFF

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setting laser cut software tool

Software's Graphical User

Interface that controls the

laser cutting tool.

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covered the copper plate using black paint

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laser cutting of the painted copper plate

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engraving the copper plate with the FeCI3

To engraving the copper

plate, we used a corrosive

liquid, the ferric chloride

(FeCl3), often inaccurately

called "acid."

We put the ferric chloride in

a plastic container and we

immersed the copper plate

for some minutes.

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cleaning the copper plate with a solvent

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final PCB

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making holes on the final PCB

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component soldering on the final PCB

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(2) Traffic Lights: design and creation

Traffic Light design with Tinkercad

Traffic Light 3D printing session

Making holes on the Traffic Light 3D printed

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Traffic Light design with Tinkercad

Tinkercad is a simple,

online 3D design and 3D

printing app for everyone.

https://www.tinkercad.com/

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Traffic Light 3D printing session

Then we did two 3D

printing sessions. Each

session we printed two

Traffic Light.

The duration of the single

3D printing session was 2

hours and 10 minutes.

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making holes on the Traffic Light 3D printed

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attach diode LEDs inside each Traffic Lights printed

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(3) Packaging: Design and Creation

Packaging design of the TLCS prototype

Record a sheet of plexiglass using the laser cutting tool

Cut a sheet of polycarbonate using the cutting tool

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packaging design of the TLCS prototype

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record a sheet of plexiglass using the laser cutting tool

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cut and engrave a sheet of polycarbonate using the cutting tool

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(4) Final Prototype: assembling and testing

Assembly all the components to create the final packaging

Solder wires with the PCD and testing phase.

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assembly all the components to create the final packaging

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Solder wires with the PCD and testing phase

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Traffic Lights Control System(TLCS) prototype

See you in Rome next October !!!

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TLCS I/O prototype interface

GND 5V NULL

back

pedestrian

sx

pedestrian front

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Architecture

2 1

3 4

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Architecture: Three PLC System

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Logic connections between master and slaves PLC

Master Slave 1 outputs Slave 2 outputs

000 → OFF state

001 → Night state 1* , 4*

010 → Red A, Green B 0, 5, 6 4, 0, 3

011 → Red B, Green A 3, 2 6, 2, 1, 5

100 → Yellow A, Red B 1, 3 1**, 2, 5**, 6

101 → Yellow B, Red A 4, 0, 6** 3**, 0, 4

110 → Sunday (LTZ)

Green B

6 4,0,3

111 → Sunday (LTZ)

Green A

5, 6, 2,1

only bicycle and pedestrian

traffic without yellow state

**: Lamp %S5 time base 100 msecs

LTZ: Limited Traffic Zone.

*: Lamp %S6 time base 1 sec

Master PLC

● %Q0.0, %Q0.1, %Q0.2:

command bit.

● %Q0.3: buzzer n. 1.

● %Q0.4: buzzer n. 2.

● %Q0.5: buzzer n. 3.

● %Q0.6: buzzer n. 4.

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● %I0.0 Input to enable Daytime mode

● %I0.1 Input to enable Sunday mode

● %I0.5 reservation Push Button n. 1

● %I0.6 reservation Push Button n. 2

● %I0.7 reservation Push Button n. 3

● %I0.8 reservation Push Button n. 4

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15 secs 5 secs 10 secs 5 secs

Block Diagram for Daytime behavior crossroad A/B

Daytime Mode

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Master PLC - DRUM Programmer

000 configuration - all led are

switched off.

Reset leds during scenarios

variation.

DayTime no-Sunday

Red A, Green B

Yellow B

Red B, Green A

Yellow A

every 5 secs

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Nighttime Mode

001 → Night state NightTime no-Sunday

A-B Direction

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Reservation Mode

simulate button push along B Direction

simulate button push along A Direction

buttons n. 2 - 4

buttons n. 1 - 3

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Reservation Mode

Green B AND Reservation B Direction

Green A AND Reservation A Direction

buzzer n. 2

buzzer n. 4

buzzer n. 3

buzzer n. 1

100 → Yellow A, Red B

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Reservation Mode

direction A - pedestrian reservation

0.5’’

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101 → Yellow B, Red A

direction B - pedestrian reservation

0.5’’

Reservation Mode

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Sunday Mode

Time base: 1 min

1

1

0

1

1

1

110 Green B

111 Green A

30 secs

30 secs

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Architecture of Slaves PLC

Output PLC Slave 1 PLC Slave 2

0 RcA RpA

1 YcA GpA

2 GcA RpB

3 RcB GpB

4 YcB RbA

5 GcB GbA

6 GbB RbB

Where:

● RcA, RpA, RbA are respectively the red lights of car, pedestrian, bicycle

in A direction;

● GcA, GpA, GbA are respectively the green lights of car, pedestrian, bicycle

in A direction;

● RcB, RpB, RbB are respectively the red lights of car, pedestrian, bicycle

in B direction;

● GcB, GpB, GbB are respectively the green lights of car, pedestrian, bicycle

in B direction;

● YcA, YcB are respectively the yellow lights of car along A and B direction;

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Slave 1 PLC

● %I0.0, %I0.1, %I0.2 Input coming from

the output of Master as command

001 → Night state

010 → Red A, Green B

011 → Red B, Green A

100 → Yellow A, Red B

101 → Yellow B, Red A

110 → Sunday Green B

%Q0.0,

%Q0.1

%Q0.2

%Q0.3

%Q0.4

%Q0.5

CAR along A-B direction

%Q0.6

A

B

B

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COMMAND 010

TURN O

N

TURN O

FF

Slave 1 PLC - Red A, Green B

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COMMAND 101

TURN O

N

TURN O

FF

Slave 1 PLC - Red A, Yellow B

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COMMAND 011

TURN O

N

TURN O

FF

Slave 1 PLC - Red B, Green A

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COMMAND 100

TURN O

N

TURN O

FF

Slave 1 PLC - Yellow A, Red B

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TURN O

N

TURN O

FF

COMMAND 001

0.5’’

Slave 1 PLC - NightTime

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TURN O

FF

COMMAND 111

Slave 1 PLC - Sunday Time, Reset

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TURN O

FF

COMMAND 110

TURN O

N Slave 1 PLC - Sunday Time

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Slave 2 PLC

● %I0.0, %I0.1, %I0.2 Input coming

from the output of Master as

command

010 → Red A, Green B

011 → Red B, Green A

100 → Yellow A, Red B

101 → Yellow B, Red A

110 → Sunday Green B

111 → Sunday Green A

%Q0.0

%Q0.1

%Q0.2

%Q0.3

Pedestrian lights

%Q0.4

%Q0.5

%Q0.6

A

B

A

B

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COMMAND 010

TURN O

N

TURN O

FF

Slave 2 PLC - Red A, Green B

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COMMAND 101

TURN O

N

TURN O

FF

Slave 2 PLC - Red A, Yellow B

0.05’’

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COMMAND 011

TURN O

N

TURN O

FF

Slave 2 PLC - Red B, Green A

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Slave 2 PLC - Yellow A, Red B

COMMAND 100 TURN O

N

TURN O

FF

0.05’’

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Slave 2 PLC - LTZ, Green B, Red A

COMMAND 110

TURN O

N

TURN O

FF

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Slave 2 PLC - LTZ, Green A, Red B TURN O

N

TURN O

FF

COMMAND 111

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GRAZIE PER L’ATTENZIONE