LIFT CONTROL USING SIEMENS PLC

Main Project report submitted in partial fulfillment of the requirements

for the award of the degree of
BACHELOR OF TECHNOLOGY
IN
ELECTRICAL AND ELECTRONICS ENGINEERING

BY

PRASHANTH.K (10241A0227)
SRUJAN.P (10241A0243)
PRUDHVI.M (10241A0239)
RAJAGOPALAN.G (10241A0217)

Under the guidance of
V.V.S.MADHURI
(Asst Professor)



2013-2014

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING
GOKARAJU RANGARAJU INSTITUTE OF ENGINEERING AND
TECHNOLOGY, Hyderabad, Andhra Pradesh.



GOKARAJU RANGARAJU INSTITUTE OF ENGINEERING &
TECHNOLOGY
Hyderabad, Andhra Pradesh.



DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

C E R T I F I C A T E

This is to certify that the project report entitled Lift Control Using Siemens
PLC that is being submitted by K.Prashanth , P.Srujan , M.Prudhvi ,
G.Rajagopalan in partial fulfilment for the award of the Degree of Bachelor of
Technology in Electrical and Electronics Engineering to the J awaharlal
Nehru Technological University is a record of bonafide work carried out by her
under my guidance and supervision. The results embodied in this project report
have not been submitted to any other University or Institute for the award of any
graduation degree.





Project Guide:
Dr.M.Chakravarthy V.V.S Madhuri
HOD-EEE, Asst. Professor
GRIET. EEE, GRIET.

External Examiner













ACKNOWLEDGEMENT


This is to place on record our appreciation and deep gratitude to the persons without
whose support this project would never see the light of day.
We wish to express our propound sense of gratitude to Mr. P. S. Raju, Director,
G.R.I.E.T for his guidance, encouragement, and for all facilities to complete this project.
We are highly indebted to Mr. P. M. Sarma, DEAN (R & D), G.R.I.E.T for his
guidance and constant supervision as well as for providing necessary information regarding
the project & also for his support in completing the project.
We are humbled by the encouragement received from Dr. M. Chakravarthy, HOD,
EEE Department, G.R.I.E.T throughout the project.
We also express our sincere thanks to Sri P.P.C.Prasad, Associate Professor,
Mechanical Department, G.R.I.E.T for extending his help.
We have immense pleasure in expressing our thanks and deep sense of gratitude to
our guide V.V.S Madhuri , Assistant Professor, Department of Electrical and Electronics
Engineering, G.R.I.E.T for her guidance throughout this project.
We express our gratitude to Mr. E. Venkateshwarlu, Associate Professor, Department
of Electrical and Electronics Engineering , G.R.I.E.T for his valuable recommendations and
for accepting this project report.
Finally we express our sincere gratitude to all the members of faculty and our friends
who contributed their valuable advice and helped to complete the project successfully.

BATCH A-9:

K.Prashanth -10241A0227

P.Srujan - 10241A0243

M.Prudhvi - 10241A0239

G.Rajagopalan - 10241A0217







ABSTRACT:

This paper describes the use of SIEMENS S7-1200 Programmable Logic Controller to
instruct a four-floor elevator system. PLCs have proven to be able to withstand harsh
environments and this made them very popular in industrial process control. Though
practically elevators are not controlled by PLC, still we employed it, because elevator is an
appropriate system where we can explore a lot of features of the PLC. The PLC system just
makes things easier for the design and maintenance engineer. The PLC Systems are very
useful for Industrial Automation, alone which can replace many number of equipments like
contactors, switches etc. PLC systems are very practical technologies and their mastery will
no doubt boost the student skills in his daily technical life since the system is approached
from both hardware and software design perspectives. As it is a mere model while shifting to
a practical elevator some of the modules must be replaced.
.























CONTENTS
Page No.
Abstract
Table of Contents
1. Introduction 1
2. Programmable Logic Controller 5
2.1 PLC history 5
2.2 PLC characteristics 6
2.3 How PLC works 9
2.4 PLC programming language 11
2.5 Human Machine Interface 15
2.6 PLC Applied in Elevator System Applications 16
3. Variable Frequency Drive 17
4. Induction Machine 22
5. Construction of Elevator 25
5.1 Hardware Design 26
5.2 Design of Elevator Cabin 26
5.3 Counter Weight Balance 26
5.4 Rope Strength 27
6. Software Design 30
7. System Debug 34
7.1 Hardware debug 35
7.2 Software debug 36
Result 37
Summary 44
References 45






1














CHAPTER-1
INTRODUCTION
















2





INTRODUCTION:

Due to the cause of rapid population growth at the cities and multi-stored buildings, the
need of elevators is being increased. With the rising life standards and attention to human and
with the technologic developments, elevator systems are getting better, more fast, stronger and
better quality elevators are produced. Previously, most systems were focused on the mounting of
elevators, especially after the 1980s the need for elevator maintenance and fault staff have been
started to increase. For instance, automatic doors have being used instead of splash doors,
microprocessor electronic cards have being used instead of cards with relay, double-speed or
speed-controlled elevators have being used instead of one-speed elevators. Such developments
provide to improve the quality in elevator systems, develop and diverse the used setting and
maintenance or repair tools and Instruments and therefore facilitation of the work compared to
previous years and increase the reliability of elevator. Some of the drawbacks of the traditional
system are
The control system have high failure rate that were mainly due to numerous contacts,
complexity of wiring circuit. In addition, electrical contacts were easy to burn out, which
could result in poor contact.
Electrical controller and hardware wiring based on common method were difficult to
achieve a more complex control function.
Electromagnetic actuator and contact action were so slow, mechanical and
electromagnetic have large inertia. Therefore, the control precision of system was
difficult.
Some of the developments that have made to overcome the disadvantages of previously used
elevators are

The traditionally used relays and IC boards have been replaced by PLC for easy and
cheap controlling of machines used in the elevator.
Also by the use of PLC we can integrate monitoring softwares like Intouch, Citech, etc.
In order to control the motion of the elevator cabin smoothly AC motors are used
because of its advantage of easy controlling and fast acceleration and deceleration.
To achieve high speed nine-phase Permanent Magnet Synchronous Motor has been used.
To reduce the size of the machine room and for smooth operation Linear Induction Motor
has been used.
In some cases Linear Switched Reluctance Motor (LSRM) has been used because of the
absence of windings both in stator as well as in the rotor even though it is having some
disadvantages like difficulty in motor controlling and generation of ripples.


3







Block diagram:

Based upon the need the blocks have been developed and drawn as block diagram
Figure1



Fig: 1.1 Block Diagram
The figure depicts the block diagram of a PLC based Elevator. Supply is given to both
the PLC controller as well as to the motor. This is attached with the elevator cabin with the use
of Reed Switches (sensing device) the position of the cabin will be determined and the cabin is
made to work accordingly. The V/F drive system for The Speed control of the motor is used.






4













CHAPTER-2
PROGRAMMABLE LOGIC CONTROLLER (PLC)






5





Programmable Logic Controller (PLC)

2.1 PLC History:
In the late 1960's PLCs were first introduced. The primary reason for designing such a
device was eliminating the large cost involved in replacing the complicated relay based machine
control systems. Bedford Associates (Bedford, MA) proposed something called a Modular
Digital Controller (MODICON) to a major US car manufacturer. Other companies at the time
proposed computer based schemes, one of which was based upon the PDP-8. The MODICON
084 brought the world's first PLC into commercial production.
When production requirements changed so did the control system. This becomes very
expensive when the change is frequent. Since relays are mechanical devices they also have a
limited lifetime which required strict adhesion to maintenance schedules. Troubleshooting was
also quite tedious when so many relays are involved. Now picture a machine control panel that
included many, possibly hundreds or thousands, of individual relays. The size could be mind
boggling. How about the complicated initial wiring of so many individual devices! These relays
would be individually wired together in a manner that would yield the desired outcome. As can
be seen, there were many problems with this relay based design.
These "new controllers" also had to be easily programmed by maintenance and plant
engineers. The lifetime had to be long and programming changes easily performed. They also
had to survive the harsh industrial environment. That's a lot to ask! The answers were to use a
programming technique most people were already familiar with and replace mechanical parts
with solid-state ones.
In the mid70's the dominant PLC technologies were sequencer state-machines and the
bit-slice based CPU. The AMD 2901 and 2903 were quite popular in Modicon and A-B PLCs.
Conventional microprocessors lacked the power to quickly solve PLC logic in all but the
smallest PLCs. As conventional microprocessors evolved, larger and larger PLCs were being
based upon them. However, even today some are still based upon the 2903. (Ref A-B's PLC-3)
Modicon has yet to build a faster PLC than their 984A/B/X which was based upon the 2901.
6

Communications abilities began to appear in approximately 1973. The first such system
was Modicon's Modbus. The PLC could now talk to other PLCs and they could be far away from
the actual machine they were controlling. They could also now be used to send and receive
varying voltages to allow them to enter the analog world. Unfortunately, the lack of
standardization coupled with continually changing technology has made PLC communications a
nightmare of incompatible protocols and physical networks. Still, it was a great decade for the
PLC.
The 80's saw an attempt to standardize communications with General Motor's
manufacturing automation protocol (MAP). It was also a time for reducing the size of the PLC
and making them software programmable through symbolic programming on personal computers
instead of dedicated programming terminals or handheld programmers. Today the world's
smallest PLC is about the size of a single control relay.
The 90's have seen a gradual reduction in the introduction of new protocols, and the
modernization of the physical layers of some of the more popular protocols that survived the
1980's. The latest standard (IEC 1131-3) has tried to merge plc programming languages under
one international standard. We now have PLCs that are programmable in function block
diagrams, instruction lists, C and structured text all at the same time! PC's are also being used to
replace PLCs in some applications. The original company who commissioned the MODICON
084 has actually switched to a PC based control system.


2.2 PLC Characteristics:
SIMATIC S7-1200

In the field of automation, powerful components are a key factor to success. But what
really gives us a unique advantage, is all of them working together. The new modular SIMATIC
S7-1200 controller provides simple but highly precise Automation tasks.

The SIMATIC S7-1200 controller is modular and compact, versatile, a secure
investment, and is powerfully fit for a full range of applications. It features an integrated
PROFINET interface, powerful integrated technology functions and a highly scalable and
flexible design, a communication interface that fulfills the highest standards of industrial
communication and a full range of powerful integrated technology functions make this controller
an integral part of a complete and comprehensive automation solution.




7



Scalable and flexible design:

The SIMATIC S7-1200 controller family was designed with maximum flexibility to fit
any individual machine requirements. This allows us to custom design our controller system to
meet the requirements; it also makes future system expansions quick and easy.


Industrial communication:

The SIMATIC S7-1200s integrated PROFINET interface provides seamless
communication with the SIMATIC STEP 7 Basic engineering system for programming, with
SIMATIC HMI Basic Panels for visualization, with additional controllers for PLC-to-PLC
communication and with third-party devices for advanced integration options.

Integrated technology:

The name SIMATIC has been a reliable symbol in the field of automation for many
years. They have integrated proven and innovative technology functions into the new controller
ranging from counting and measuring, speed, position and duty cycle control to simple process
control functionality. This wide variety of functionality guarantees the ability to solve a wide
array of applications based on technology that has proven its validity in the field for many years.
Up to 3 communication modules can be added to any of the SIMATIC S7-1200 CPUs. The
RS485 and RS232 communication modules provide the connection for performing point-to-point
serial communication.

High-speed inputs & outputs:

The new SIMATIC S7-1200 controller comes with 6 high-speed counters. Three inputs at
30 kHz are integrated for counting and measuring.
Two high-speed pulse train outputs at 100 kHz are integrated for controlling the speed
and position of a stepper motor or a servo drive. They can alternatively be used as pulse-width-
modulated outputs for controlling the speed of a motor, position.



Memory:

Up to 50 KB of integrated work memory is provided with a floating boundary between
the user program and user data. Up to 2 MB of integrated load memory and 2 KB of integrated
retentive memory are also provided. The optional SIMATIC Memory Card provides an easy way
to transfer programs to multiple CPUs. This card can also be used for storing miscellaneous files
or to update the firmware of the controller system.


8



Signal modules:

Up to eight signal modules can be connected to the largest CPUs for the support of
additional digital and analog I/Os. With the addition of a signal board, you can increase the
number of digital or analog I/Os on the controller to custom-fit your needs without increasing
the controllers footprint. The SIMATIC S7-1200 system comes in three different models, CPU
1211C, CPU 1212C and CPU 1214C, that may each be expanded to exactly fit your machine
requirements. One signal board can be added inside the front of any CPU to easily expand the
digital or analog I/Os without affecting the physical size of the controller. Signal modules can
be connected to the right side of the CPU to further expand the digital or analog I/O capacity.
CPU 1212C accepts two and CPU 1214C accepts eight signal Modules. CPU 1214C has a width
measuring only 110 mm and both the CPU 1212C and CPU 1211C are only 90 mm wide.
Together with the small footprint of the communication modules and signal modules, this
modular and compact system saves valuable space and offers you the highest level efficiency and
flexibility during the installation process.

High-speed outputs for speed, position or duty cycle control, two high-speed outputs are
integrated into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulse-
width-modulated outputs. When configured as a PTO, a 50 percent duty cycle pulse train is
provided at a rate of up to 100 kHz for the open-loop speed and position control of stepper
motors and servo drives. Feedback for the pulse train outputs is provided internally using two of
the high-speed counters. When configured as a PWM output, a fixed cycle time output with a
variable duty cycle is provided for controlling the speed of a motor, position of a valve, or duty
cycle of a heating element.






Fig: 2.1 SIMATIC S7-1200
9

CPU 1212C
DI 8x24 V DC, DQ 6x24 V DC or 6xRLY, AI 2x10 Bit 010 V DC
DC/DC/DC 6ES7 212-1AD30-0XB0
AC/DC/RLY 6ES7 212-1BD30-0XB0
DC/DC/RLY 6ES7 212-1HD30-0XB0




2.3 How PLC works:

There are four basic steps in the operation of all PLCs: which continually take place in a
repeating loop: Input Scan, Program Scan, Output Scan and Housekeeping.


Fig: 2.2 PLC Working Cycle

Input Scan: Detects the state of all input devices that are connected to the PLC
Program Scan: Executes the user created program logic.
Output Scan: Energizes or de-energize all output devices that are connected to the PLC.
Housekeeping: This step includes communications with programming terminals, internal
diagnostics etc...

1. CHECK INPUT STATUS:
First the PLC takes a look at each input to determine if it is on or off. In other words, is
the sensor connected to the first input on? , Then the second input? , Then the third and so on
It records this data into its memory to be used during the next step.
2. EXECUTE PROGRAM:
Next the PLC executes your program one instruction at a time. Maybe the program says
that if the first input was on then it should turn on the first output. Since it already knows which
inputs are on/off from the previous step it will be able to decide whether the first output should
be turned on based on the state of the first input. It will store the execution results for use later
during the next step.
3. UPDATE OUTPUT STATUS:
10

Finally the PLC updates the status of the outputs. It updates the outputs based on which
inputs were on during the first step and the results of executing your program during the second
step.

Based on the example in step 2 it would now turn on the first output because the first
input was on and your program said to turn on the first output when this condition is true. After
the third step the PLC goes back to step one and repeats the steps continuously. One scan time is
defined as the time it takes to execute the 3 steps listed above.

The basic elements of a PLC include input modules or points, a central processing unit
(CPU), output modules or points, and a programming device. The type of input modules or
points used by a PLC depends upon the types of input devices used. Some input modules or
points respond to digital inputs, also called discrete inputs, which are either on or off. Other
modules or inputs respond to analog signals. These analog signals represent machine or process
conditions as a range of voltage or current values. The primary function of a PLCs input
circuitry is to convert the signals provided by these various switches and sensors into logic
signals that can be used by the CPU.

The CPU evaluates the status of inputs, outputs, and other variables as it executes a
stored program. The CPU then sends signals to update the status of outputs. Output modules
convert control signals from the CPU into digital or analog values that can be used to control
various output devices. The programming device is used to enter or change the PLCs program
or to monitor or change stored values. Once entered, the program and associated variables are
stored in the CPU. In addition to these basic elements, a PLC system may also incorporate an
operator interface device to simplify monitoring of the machine or process.

In our case the input module will be composed of an array of switches that help us to
input Logic ones or Logic zeros to the PLC; the output module is made of LEDs to display the
status of the system; our programming device is the SIEMENS provided STEP 7 MicroWin and
the operator interface is a WinCC based Human Machine Interface, herein referred to HMI


Fig: 2.3 PLC Working Principle Block Diagram



11




2.4 PLC Programming Language:

2.4.1 Types of Programming:

1. Ladder diagram (LD):
Ladder diagram is a graphic programming language derived from the circuit diagram of
directly wired relay controls. The ladder diagram contains contact rails to the left and the right of
the diagram; these contact rails are connected to switching elements (normally open / normally
closed contacts) via current paths and coil elements.


Fig: 2.4 Ladder program section



2. Function block diagram (FBD):
In the function block diagram, the functions and function blocks are represented
graphically and interconnected into networks. The function block diagram originates from the
logic diagram for the design of electronic circuits.


Fig : 2.5 FBD Program Section





3. Sequential function chart (SFC):
The sequential function chart is a language resource for the structuring of sequence-
oriented control programs. The elements of the sequential function chart are steps, transitions,
12

alternative and parallel branching. Each step represents a processing status of a control program,
which is active or inactive. A step consists of actions which, identical to the transitions, are
formulated in the IEC 1131-3 languages. Actions themselves can again contain sequence
structures. This feature permits the hierarchical structure of control program. The sequential
function chart is therefore an excellent tool for the design and structuring of control programs.
Since Ladder Diagram is the most used method to program PLCs and particularly our method in
this project, a closer look at how some of the hardware functions are achieved is necessary.

2.4.2 LADDER LOGIC:

Ladder Logic or Ladder Diagrams is the most common programming language used to
program a PLC. Ladder logic was one of the first programming approaches used in PLCs
because it borrowed heavily from the Relay Diagrams that plant electricians already knew. The
symbols used in Relay Ladder Logic consist of a power rail to the left, a second power rail to the
right, and individual circuits that connect the left power rail to the right. The logic of each circuit
(or rung) is solved from left to right. The symbols of these diagrams look like a ladder - with two
side rails and circuits that resemble rungs on a ladder.

If Input1 is ON (or true) - power (logic) completes the circuit from the left rail to the right
rail - andOutput1 turns ON (or true).If Output1 is OFF (or false) - then the circuit is not
completed and logic does not flow to the right - and Output 1 is OFF. There are many logic
symbols available in Ladder Logic - including Timers, Counters, Math, and Data Moves- such
that any logical condition or control loop can be represented in Ladder Logic. With just a handful
of basic symbols - a Normally Open Contact, Normally Closed Contact, Normally Open Coil,
Normally Closed Coil, Timer, Counter - most logical conditions can be represented .With just
the Normally Open Contact and Normally Open Coil - a surprising array of basic logical
conditions can be represented.





2.4.3 Commonly used Blocks:

1. Normally Open Contact.:
This can be used to represent any input to the control logic - a switch or sensor, a contact
from an output, or an internal output. When "solved" the referenced input is examined for an ON
(logical 1) condition. If it is ON, the contact will close and allow power (logic) to flow from left
to right. If the status is OFF, the contact opens and power will not flow from left to right.

Fig 2.6:Normally Open Contact


13







2. Normally Open Coil:
This can be used to represent any discrete output from the control logic. When "solved" if
the logic to the left of the coil is TRUE, the referenced output is ON (logical 1).

Fig 2.7: Normally Open Coil



3.Solving a Single Rung:
Suppose a switch is wired to Input1, and a light bulb is wired through Output1 in such a
way that the light is OFF when Output1 is OFF, and ON when Output1 is ON. When Input1 is
OFF (logical 0) the contact remains open and power cannot flow from left to right. Therefore,
Output1 remains OFF (logical 0).When Input1 is ON (logical 1) then the contact closes, power
flows from left to right, and Output1 becomes ON (the light turns ON).


Fig 2.8: Contacts powering a coil




4. The AND Rung:
The AND is a basic fundamental logic condition that is easy to directly represent in
Ladder Logic. Suppose a switch is wired to Switch1, a second switch is wired toSwitch2, and a
light bulb is wired through Light1 in such a way that the light is OFF when Light1 is OFF, and
ON when Light1 is ON. In order for Light1 to turn ON, Switch1 must be ON, AND Switch2
must be ON. If Switch1 is OFF, power (logic) flow from the left rail, but stops at Switch1.
Light1 will be OFF regardless of the state of Switch2.If Switch1 is ON, power makes it to
Switch2. If Switch2 is OFF, power cannot flow any further to the right, and Light1 is OFF. If
Switch1 is ON, AND Switch2 is ON - power flows to Light1 solving its state to ON.



14









5. The OR Rung:
The OR is a logical condition that is easy to represent in Ladder Logic. Suppose a switch
is wired to Switch1, a second switch is wired to Switch2, and a light bulb is wired. Through
Light1 in such a way that the light is OFF when Light1 is OFF, and ON when Light1 is ON. In
this instance, we want to the light to turn ON if either Switch1 OR Switch2 is ON. If Switch1 is
ON - power flows to Light1 turning it ON. If Switch2 is ON - power flows through the Switch2
contact, and up the rail to Light1 - turning it ON. If Switch1 AND Switch 2 are ON - Light1 is
ON. The only way Light1 is OFF is if Switch1 AND Switch2 are OFF.


AND logic OR logic

Fig. 2.9 OR logic
2.4.4 Register allocation:
In this section, we allocate some specific registers that will be used in our project. Also
their functions will be introduced briefly.
Position register: this register tells us the current location of the lift vehicle.4 bits are
reserved and bit3 ,bit 2 ,bit 1 and bit0 relate to 1F,2F,3F and 4F respectively.MB0 provided by
the S7 1200 system has been used for this purpose.
Destination Registers (Updest and Downdest): When a destination request PB is pushed, a
corresponding bit is set in the appropriate destination register. 4 bits are reserved and bit3, bit 2,
bit 1 and bit0 relate to 1F, 2F, 3F and 4F respectively.MB1 and MB2 provided by the S7 1200
system have been used Updest and Downdest respectively. A particular register can be called
using %MBxx , where xx is the number of the register.


Floor Control Register:
Program control has been achieved by energizing some coils and leaving others OFF
depending on the pursued goal. For example, if the lift is located on the 1F, we energize the
initialization block, the destination scan block and the PB scan block of the 1F.Other floor
control bits are left in their OFF state at this time. It should be noted that the same applies to the
15

2F, 3F and 4F respectively. Bit 1, 2, 3 and 4 of the MB5 Register have been used to control the
1F, 2F, 3F and the 4F respectively.
Motion control:
The function of these bits is to tell whether the lift vehicle is in motion or not. Also,
when it is in motion, we need to know if it is moving up or down. Bit 0 of MB3 has been used
for motion control and bit1 of the same byte has been used for motion direction control.
On top of the above mentioned registers and bits, a great number of other registers have been
used for other purposes such as latching, temporary storage and the like. Numerous timers and in
particular 10 ms resolution timers have been used for delay purposes. For example passage from
floor to floor has been achieved using timer delays.



2.5 Human Machine Interface:
A human machine interface (HMI) is an interface which permits interaction between a
human being and a machine. Human machine interfaces vary widely, from control panels for
nuclear power plants to the screen and input buttons on a cell phone. Designing such interfaces is
a challenge, and requires a great deal of work to make the interface functional, accessible,
pleasant to use, and logical. Some engineers specialize in developing human machine interfaces
and changing the ways in which people interact with machines and systems.

Two components are needed in a human machine interface. The first is an input. A
human user needs some way to tell the machine what to do, to make requests of the machine, or
to adjust the machine. Examples of input devices include keyboards, toggles, switches, touch
screens, joysticks, and mice. All of these devices can be utilized to send commands to a system
or even an interlinked set of systems.

The interface also requires an output, which allows the machine to keep the human user
updated on the progress of commands, or to execute commands in physical space. On a
computer, for example, users have a screen which can display information. A robot, on the other
hand, may move in response to commands and store data on a hard drive so that people can see
how the robot responds, learns, and navigates the world. Outputs can also include things as
simple as status lights which alert people when toggles or switches have been activated.

The technology behind the human machine interface is constantly improving.
Researchers have developed interfaces which can be controlled with the mind, for example,
seeing applications for this technology among stroke patients and other people with severely
restricted modes of communication. Likewise, outputs have become much more sophisticated
over time.

As many people have noted, a poorly designed human machine interface can be
extremely frustrating. On one end of the scale, the interface may be buggy or nonfunctional,
causing difficulty because it does not work as intended. On the other end of the scale, the
interface works, but it is designed in such a way that it is confusing and challenging to operate
because it is not intuitive for users. The art of designing intuitive interfaces requires a deep
understanding of how humans interact with their environment and an awareness of the
16

psychology of designing interfaces in a way which will be accessible to a broad spectrum of
humans. What works for an engineer in a human machine interface, for example, might not be as
easy for a member of the general public.





2.6 PLC Applied in Elevator System Applications:

With latest developments in science and technology, PLC technologies have been widely
applied in industrial control). A lot of factory production lines, processing equipment, ship
loading and unloading device, the operation of the elevator are controlled by the PLC, as long as
the scheduled control tasks are compiled in the form of a string of instructions and stored in the
memory. It is the job of PLC to drive the output devices in response to input signals present at its
Input ports.

PLC application in elevator systems is also very mature. PLC act as the master
controller, on one hand it collects a variety of input signals of the elevator, including the
location of the elevator, state of the signal of internal and external command button, the door
lock signal, the door zone signal, forced to slow down ,the signal within the wells and fire
signals. On the other hand, based on signals it has such as the elevator floor signal and speed
signal, switch gate signal, the directional relay and brake relay it runs its calculations to control
the operation of the elevator.

Conditional branches are usually used in elevator applications; the program is broken into
several functional blocks such as normal acceleration, steady speed, slow down and the like. On
power on it starts its working cycle and scans for inputs and decides what to do based on the
program burned into its memory.











17












CHAPTER-3
VARIABLE FREQUENCY DRIVE (VFD)







18






Variable Frequency Drive
A Variable Frequency Drive (VFD) is a type of motor controller that drives an electric
motor by varying the frequency and voltage supplied to the electric motor. Other names for a
VFD are variable speed drive, adjustable speed drive, adjustable frequency drive, AC
drive, Microdrive, and inverter.
Frequency (or hertz) is directly related to the motors speed (RPMs). In other words, the
faster the frequency, the faster the RPMs go. If an application does not require an electric motor
to run at full speed, the VFD can be used to ramp down the frequency and voltage to meet the
requirements of the electric motors load. As the applications motor speed requirements change,
the VFD can simply turn up or down the motor speed to meet the speed requirement
19

.
Fig: 3.1 A Commercial Variable Frequency Drive
For the speeds below rated speed for large variation of voltage, small change in speed
occurs. Therefore normally v/f control is used. In this method, voltage and frequency are
varied with respect to each other, so that the ratio is maintained constant. Therefore the flux
density will be maintained constant. But this method requires A Converter- Inverter circuit at the
stator side.






20


Fig: 3.2 Circuit Diagram Of VFD











The pin diagram configuration of VFD is below
21


Fig: 3.3 Block Diagram and Pin Configuration Of VFD







Feature Benefits
22






















Table 3.1 Features and Benefits of SIMATIC S7-1200


Soft starting Reduced impact on electrical network means no
penalties from utility
Reduced stress on motor, coupling and load, giving
extended life time
Unlimited number of starts per hour
Precise speed and torque control Better product quality
Improved cost of ownership
Better protection of motor (e.g. stall protection and
load)
Consistent product quality, despite input power
variations and sudden load changes
Wide speed control range Improved efficiency compared to traditional flow
control methods e.g. damper control, throttling.
lower maintenance
High reliability and availability Reduced downtime
Improved process availability
Low audible noise
Improved working environment for operators
Capability for speed reversal / regenerative
braking
Desired torque during braking, therefore better
product quality
improved braking characteristics
Higher efficiency
Flux optimisation (motor flux automatically
adapted to load)
Improved motor efficiency
Reduced motor noise
Power loss ride through Reduced number of drive trips
Better process availability
23








CHAPTER-4
INDUCTION MACHINES









INDUCTION MACHINES:
24


An induction or asynchronous motor is an AC electric motor in which the electric
current in the rotor needed to produce torque is induced by electromagnetic induction from the
magnetic field of the stator winding. An induction motor therefore does not require mechanical
commutation, separate-excitation or self-excitation for all or part of the energy transferred from
stator to rotor, as in universal, DC and large synchronous motors. An induction motor's rotor can
be either wound type or squirrel-cage type.
Three-phase squirrel-cage induction motors are widely used in industrial drives because
they are rugged, reliable and economical. Single-phase induction motors are used extensively for
smaller loads, such as household appliances like fans. Single phase Induction machines do not
have good starting torque and it is not a self-starting machine .It requires an extra circuitry for
providing self-starting. VFDs offer especially important energy savings opportunities for existing
and prospective induction motors in variable-torque centrifugal fan, pump and compressor load
applications. Three phase motors can have a high starting Torque and can be able to rotate in
both forward and reverse direction by reversing the supply(R-Y-B) Terminals. They are also
available in a range of sizes from a fraction of one horse-power to many thousands of HP.


Fig: 4.1 Internal Structure of 3-ph Induction Motor







Ratings of 3-phase induction motor used

25


0.3 KW
Speed : 1390 RPM
Rated voltage : 415 V
Rated current : 1.02A
Duty - s1
Connection : Star
Frequency : 50 hz
Efficiency : 70%
IP 55
A0C 50


























26









CHAPTER-5
CONSTRUCTION OF ELEVATOR















CONSTRUCTION OF ELEVATOR:

5.1 Hardware Design:
27

This chapter discuss about the design of an elevator by the calculation of certain
parameters which defines the operation of the elevator. To meet the objectives of the project that
has been derived from the previously completed theoretical studies a machine model has been
designed. Then to validate and to implement the simulated model as a prototype certain
calculations have been carried out to determine some critical parameters. The parameters
includes the size of the cabin, maximum number of persons can be accommodated into the
elevator, strength of the rope, type of motor used, motors power rating and torque rating. The
important part of the system is the controller the type of controller used here is PLC.
Electromagnetic actuator and contact action were so slow, mechanical and electromagnetic
components have large inertia. Therefore the control precision of system was difficult. So there
is a need to go for modern type of controllers like PLC. In this type of control there is provision
to monitor the entire system by means of SCADA.

5.2. Design of elevator cabin
The elevator cabin is designed by having in mind the number of passengers it is going to
accommodate. Also it should have the capacity to bear the weight of the passengers travelling in
the elevator. But here, it is just a demonstration. So, neglect the amount weight to be carried out
by cabin.

The tension on the rope and its choice of selection can be determined with the following
simple calculation. The force excreted on the rope can be found by using Newtons
formula.
The weight of the elevator cabin constructed is 2.5Kg.

5.3. Counter Weight Balance:
As the weight of the Counter-Weight should be equal to the weight of the Elevator cabin,
a iron dead weight of 2.5 kg is molded in a rectangular shape such that it moves freely along with
the elevator cabin


5.4 Rope Strength:
The force which acts on the rope can be found out by the following calculation
F=mg
F=3*9.8=29.4N
The force acting on the string is 29.4N. So a string with the capacity to bear at least has to be
chosen for 40N.



28


Table: 5.1 Rope Calibration
5.4 Sensors:
Reed Switch is used as a sensor to determine the position of the lift. The reed switch is
an electrical switch operated by an applied magnetic field. It was invented at Bell Telephone
Laboratories in 1936 by W. B. Ellwood. The reed switch contains a pair (or more) of
magnetizable, flexible, metal reeds whose end portions are separated by a small gap when the
switch is open. The reeds are hermetically sealed in opposite ends of a tubular glass envelope.
The contacts may be normally open, closing when a magnetic field is present, or normally closed
and opening when a magnetic field is applied. The switch may be actuated by a coil, making a
reed relay or by bringing a magnet near to the switch. Once the magnet is pulled away from the
switch, the reed switch will go back to its original position.
29


Fig: 5.1 Reed Sensor
A magnetic field (from an electromagnet or a permanent magnet) will cause the reeds to come
together, thus completing an electrical circuit. The stiffness of the reeds causes them to separate,
and open the circuit, when the magnetic field ceases. Another configuration contains a non-
ferrous normally-closed contact that opens when the ferrous normally-open contact closes. Good
electrical contact is assured by plating a thin layer of non-ferrous precious metal over the flat
contact portions of the reeds; low-resistivity silver is more suitable than corrosion-resistant gold
in the sealed envelope. There are also versions of reed switches with mercury "wetted" contacts.
Such switches must be mounted in a particular orientation otherwise drops of mercury may
bridge the contacts when not activated.

Fig. 5.2 Working condition of Reed Switch
30

Since the contacts of the reed switch are sealed away from the atmosphere, they are
protected against atmospheric corrosion. The hermetic sealing of a reed switch make them
suitable for use in explosive atmospheres where tiny sparks from conventional switches would
constitute a hazard.
One important quality of the switch is its sensitivity, the amount of magnetic field
necessary to actuate it. Sensitivity is measured in units of Ampere-turns, corresponding to the
current in a coil multiplied by the number of turns. Typical pull-in sensitivities for commercial
devices are in the 10 to 60 AT range. The lower the AT, the more sensitive the reed switch. Also,
smaller reed switches, which have smaller parts, are more sensitive to magnetic fields, so the
smaller the reed switch's glass envelope is, the more sensitive it is. They usually range in length
from 2.0 inches long to as small as 0.025 inches long.

Fig: 5.3 Dimensions of Reed Switch
In production, a metal reed is inserted in each end of a glass tube and the end of the tube
heated so that it seals around a shank portion on the reed. Infrared-absorbing glass is used, so an
infrared heat source can concentrate the heat in the small sealing zone of the glass tube. The
thermal coefficient of expansion of the glass material and metal parts must be similar to prevent
breaking the glass-to-metal seal. The glass used must have a high electrical resistance and must
not contain volatile components such as lead oxide and fluorides. The leads of the switch must
be handled carefully to prevent breaking the glass envelope.







31








CHAPTER-6
SOFTWARE DESIGN










32

SOFTWARE DESIGN:
The programming for PLC is done on SIMATIC STEP 7 Basic (TIA Portal) which is a
price-optimized subset of STEP 7 Professional controller software.
TIA Portal Basic has task-oriented, intelligent and intuitive editors that enable it to serve
as one common engineering framework for the SIMATIC S7-1200 controller and SIMATIC
HMI Basic Panel; which will help to achieve many engineering efficiencies in daily work giving
a competitive advantage.
Compact automation solutions also require scalability and flexibility, and this is achieved
for your application through the integrated PROFINET interface on the controller S7-1200 for
programming, HMI connections, distributed I/O's and distributed drive architectures.





The following are the blocks of the line program:







33


Fig: 6.1 Scanning the Present Locations



34



Fig: 6.2 Assigning Inputs and deciding motor direction





35




Fig: 6.3 Motor Action according to the user command











36









CHAPTER-7

SYSTEM DEBUGGING














37

Debugging:

System Debug:
In computers, debugging is the process of locating and fixing or bypassing bugs (errors)
in computer program code or the engineering of a hardware device. To debug a program or
hardware device is to start with a problem, isolate the source of the problem, and then fix it. A
user of a program that does not know how to fix the problem may learn enough about the
problem to be able to avoid it until it is permanently fixed. When someone says they've
debugged a program or "worked the bugs out" of a program, they imply that they fixed it so that
the bugs no longer exist.

Debugging is a necessary process in almost any new software or hardware development
process, whether a commercial product or an enterprise or personal application program. For
complex products, debugging is done as the result of the unit test for the smallest unit of a
system, again at component test when parts are brought together, again at system test when the
product is used with other existing products, and again during customer beta test, when users try
the product out in a real world situation. Because most computer programs and many
programmed hardware devices contain thousands of lines of code, almost any new product is
likely to contain a few bugs. Invariably, the bugs in the functions that get most use are found and
fixed first. An early version of a program that has lots of bugs is referred to as "buggy."

Debugging tools (called debuggers) help identify coding errors at various development stages.
Some programming language packages include a facility for checking the code for errors as it is
being written.


Hardware Debug:
The hardware debug phase involved testing each hardware module component for proper
operation. As in any circuit test, we have to make sure that the system is safely powered; we
made sure that the system has a 220V; 50Hz AC power supply and a 24V DC power supply
.These should be connected following standard safety measures. Each Light Emitting Diode has
been tested for proper operation. Here the current limiting resistors must be checked since they
are critical to the operation of the system. If not carefully chosen the LEDs may burn out as a
result of over current.

We should also be sure that the power supply has the capability to power the system. The
power supply used for this system can provide up to 3.5A.This should be more than enough for
our system since each LED needs 8~15 am or current to light properly and the maximum number
of LEDs that can be ON simultaneously is 5. To be practically sure that the hardware module
will work without problem when connected to the actual PLC we have tested it with a simple
program to power one of the output ports that we have connected to the 1F indicator LEDs for
example. With this test successful, the hardware module was approved for proper operation and
we were confident to be able to approach any further dysfunction as the situation requires.


38



Software Debug:
Software debugging is the process by which developers attempt to remove coding defects
from a computer program. It is not uncommon for the debugging phase of software development
to take 60-70% of the overall development time. In fact, debugging is responsible for 80% of all
software project overruns. Ultimately, a great amount of difficulty and uncertainty surround the
crucial process of software debugging.

This is because at each stage of the error detection process, it is difficult to determine
how long it will take to find and fix an error, not to mention whether or not the defect will
actually be fixed. In order to remove bugs from the software, the developers must first discover
that a problem exists, then classify the error, locate where the problem actually lies in the code,
and finally create a solution that will remedy the situation (without introducing other problems!).
Some problems are so elusive that it may take programmers many months, or in extreme cases,
even years to find them. Developers are constantly searching for ways to improve and streamline
the process of software debugging. At the same time, they have been attempting to automate
techniques used in error detection. Over the years, debugging technology has substantially
improved, and it will continue to develop significantly in the near future.

Since we have used the Ladder programming technique in our project we have not come
across any hard-to-solve grammatical error. This is because it is a straightforward technique and
the system warns you at any wrong move you might want to make. Several logical errors have
occurred though; and we had to find a way around this if we wanted our project to be successful.

The approach that worked was to design the software in blocks and run as many tests as
we can. Each time we were going to make a major change, we introduced a new version. This
allowed us to come back to the last best version every time we did something catastrophic.

















39














RESULT














40







Fig (a): PLC Connections:









41







Fig (b): Relay Connections:










42






Fig (c) :PLC Assembled Panel:










43






Fig (d): Motor and Pulley assembly:












44

Fig (e):VFD Panel:

45


Fig (f): Constructed Elevator Model
46



Summary:
This project involves using the S7 1200 PLC to control a four floor elevator system. The basic
functions of the elevator system have been emulated. As part of hardware design, a module for
input/output has been designed and its purpose is to provide us with different status of the
system. The SIEMENS provided software package have been used for software design and the
Ladder programming technique was used ;also, the S7 1200 PLC simulator tool was used for
quick test purposes or in case the PLC hardware was not available. Software and hardware were
tested together and possible remedies have been carried out for problems that occurred.
A Human Machine Inter face can be implemented for the visual display and control of the
PLC working and status.



























47

References:
Websites:
[1] www.siemens.com
[2] http://www.plcs.net/chapters/history2.htm
[3] http://www.scribd.com/doc/49006620/Summer-Training-Project-Report-PLC
[4] http://www.plcs.net
[5] www.wikipedia.org
[6] www.allaboutcircuits.com
[7] www.ieeecss.org

Books:
[1] Programmable Logic Controllers, W.Bolton, Elsevier-Newnes, 2009
[2] Electrical machines by J B Gupta
[3] Control Systems by Kothari