CASE STUDY BY

SHEETAL WIRELESS TECHNOLOGIES PVT LTD

FOR

WIRELESS DATA COMMUNICATION BETWEEN

STACKER AND RECLAIMER AT ACC LIMITED

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Success Case – Stacker and Reclaimer

Controlling & Monitoring Application

� Customer Information: ACC Limited Chandrapur, Maharashtra� Project handled by:

� FLSmidth Pvt Ltd. Chennai� Sheetal Wireless Technologies Pvt. Ltd. Pune� ABB Limited

� System Composition:

� Automation system consist of 3 nos. of Stackers and 3 nos. of Reclaimer moving on sixindependent rail tracks.

� Each Machine equipped with Siemens S7-300 (315-2DP) PLCs with Profibus Interface.� Each Machine equipped with Siemens S7-300 (315-2DP) PLCs with Profibus Interface.� Central Control Room equipped with ABB PLC AC800M with Profibus Interface.� MTL/Elpro, AUS Wireless Profibus Master & Slave Devices.

� Material Handled:

� Limestone, Coal and Additives.

� System Requirement:

� Remote monitoring and controlling of machines from CCR through wireless using Profibus asan interface.

� Physical signal interlock between machines (Discrete signal interlocks) and peer to peerProfibus communication, even in the absence of CCR.

� Transfer of PLC data (IO Signals and PLC information) using Profibus as a field-buscommunication.

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Limestone Stacker-Reclaimer

M/C Control

CCR

Wireless Interlocking

Machine PLC

S7-300

Stacker

M/C PLC

S7-300

Reclaimer

Control Room ABB

PLC

3

Coal Stacker-Reclaimer

Wireless Interlocking

Profibus

Control Room PLC

Reclaimer

Stacker

Circular Stacker + ReclaimerProfibus interface

Profibus interface

4

Load Center

Additive Stacker-Reclaimer

Control

CCRWireless

InterlockingProfibus interface

Load Center

Machine PLC

Remote I/O

Stacker PLC

Machine PLC

Remote I/O

Reclaimer PLC

Control Room PLC

Profibus interface

Profibus interface

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Site Photographs (Limestone Yard):

ReclaimerStacker

Rail Tracks

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� Challenges:

� All the machines are inside the Shade and about 1Km from the control room.� All the Machines moving inside the shade.� Wireless communication system needs to work without Line Of Sight and also provide reliable

communication path from CCR to each of the machine while in motion.

� Solution:

� Wireless System with true Profibus interface supporting up-to 12Mbps over physicalinterface.

� Also with On-board discrete IO’s for Interlocking and exchanging Data in peer to peer modeof communication.Frequency band suitable for Non Line Of Sight operation, that is Licensed Band UHF (400-

About Overall System in Brief

� Frequency band suitable for Non Line Of Sight operation, that is Licensed Band UHF (400-500MHz)

� Achievements:

� True Profibus Interface allowing ABB PLC to work seamlessly up-to 12Mbps with localProfibus nodes.

� Successful installation of the Radio system and accessories for reliable RF Path.� Successful commissioning of the wireless system for exchange of Data between Siemens PLC

& ABB PLC using Profibus.� Successful transfer of IO information (about 32DI + 32DO + 16AI +16AO) comprising of

about 72 Bytes of data. Wireless system capable of transferring 200Bytes of Inputs + 200Bytesof Outputs.

� Successful exchange of data including physical IO signals between machines even in theabsence of CCR.

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THANK YOU !!

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CONTACT

Sheetal Wireless Technologies Pvt. Ltd.

Pune-411038, Maharashtra, INDIA

Ph. 91-20-25422941 / 25467179 / 64007732

sales@sheetalwireless.com