AUTOMATION OF STACKER RECLAIMER USING

PROGRAMMABLE LOGIC CONTROL

Supervisor
Engr. Sadaqat Ali

Lecturer

Submitted By
Zeshan Qaisrani 13-ECT-28
Humza Liaqat 13-ECT-81
Faisal Shahzad 13-ECT-43

A Project Report submitted in partial fulfillment of the necessities

for the award of Bachelor’s Degree in
Electronics Engineering

DEPARTMENT OF ELECTRONICS ENGINEERING

UNIVERSITY OF ENGINEERING AND TECHNOLOGY
TAXILA, SUB-CAMPUS CHAKWAL
JULY 2017
1
2
 Undertaking

We declare that this project “Automation of Stacker Reclaimer Using Programmable Logic

Control” which is being submitted to University of Engineering And Technology, Taxila Sub
campus Chakwal is our own work. The material contained in this report as a whole or in parts is
not to be taken or given to whatever university or foundation for assessment.

Signature of Student 1

Zeshan Faiz

13-ECT-28

Signature of Student 2

Humza Liaqat

13-ECT-81

Signature of Student 3

Faisal Shahzad

13-ECT-43

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 Acknowledgements

We are beholden to the God for the virtuous condition and welfare that was requisite to complete
this book.

We wish to express our sincere gratitude to Sir Yaseer Arafat Durrani, Chairman of Electronics
Engineering Department (then), for assigning us with this project.

We place on record, our sincere thank you to Sir Abdul Basit, Chairman of Electronics
Engineering Department (now) for the continuous encouragement.

We are likewise grateful to Sir Faisal Masood for the supervision offered for our project. We are
tremendously beholden and indebted to him for sharing proficient, sincere and valuable guidance
and encouragement prolonged to us.

We take this juncture to prompt gratitude to all of the Department faculty affiliates for their
assistance and support. We moreover thank our parents for the perpetual inspiration, support and
attention.

We also abode on record, our sense of appreciation to one and all, which unswervingly or
ramblingly, have advanced their hand in this endeavor. 

4
 Abstract

Cement is an indispensable element of infrastructure growth. It is likewise the most important

input of the construction industry, primarily in the case of the government’s infrastructure and
housing programs, which are necessary for the
country’s socioeconomic development and evolution. Due to increasing population, various
constructional activities are increasing day by day. As a consequence the market need of cement
is also increasing continuously, but still know most of those plants aren’t up to the mark
technologically.
The whole automation process is done using programmable logic controllers (PLC)
which holds a number of unique advantages like speed, reliability, less maintenance cost
and programmability the whole scheme has been designed and tested using FATIC PLC

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 Table of Contents

Undertaking .………………………………………………………………… 3
Acknowledgments ………………………………………………………………… 4
Abstract ………………………………………………………………... 5
List of Figures ………………….………………………………………….... 8
List of Tables ………………………………………………………………. 11

1.3 Project Objectives……………………………………………………………....15

1.4 Working of project……………………………………………………………...15

1.5 Types…………………………………………………………………………....16
1.6 Applications……………………………………………………………………..16
CHAPTER 2: Literature Review…………………………………………………..17

2.1 Introduction to Automation..........................................................................17

2.2 Automation Controllers……………………………………………………18

2.3 PLC Selection Criteria…………………………………………………….20
CHAPTER 3: ELECTRICAL MODEL………………………………………24

3.1 Relay………………………………………………………………………...24
3.2 PLC…………………………………………………………………………..32
3.3 FATIK PLC……………………………………………………………..35
CHAPTER 4: INPUT /OUTPUT SYSTEM……………………………………36
4.1 Programmable Logic Controllers…………………………………………….36
4.2 Pin configuration of FATIK PLC…………………………………………….36
4.3 Inputs w.r.t. PLC………………………………………………………………...37

4.4 Outputs w.r.t PLC…………………………………………………………….38

CHAPTER 5: WORKING MODEL…………………………………………….40

5.1 Project components……………………………………………………………40

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5.2 Steps of Working Model……………………………………………………….40

5.3 process………………………………………………………………………….47

CHAPTER 6: CONCLUSIONS AND FUTURE WORK…......……………….48

6.1 Conclusions…………………...………………………………………………..48
6.2 Future work……………………………………………………….....………….49
References……………………………………..…… ……… …… ……………….50
Appendix A………………………………………………………………………….51
Appendix B……………………………………….………………………................ 52

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 List of Figures
Fig.1.1Stacker & Reclaimer…………………………………………………….15
Fig.3. 1 Omron relay…………………………………………………………….25
Fig.3. 2 Operation of relay………………………………………………………26
Fig.3.3 Different Types of Switches……………………………………………32
Fig.3.4 PLC……………………………………………………………………….33
Fig.3.5 F A T E K FBs-14MAR…………………………………………………...35
Fig. 4.1 Pin configuration of FATEK PLC………………………………………36
Fig.5.1 Limestones……………………………………………………………….41
Fig.5.2 Conveyor belts…………………………………………………………...41
Fig.5.3 DC gear motor (1)………………………………………………………..42
Fig.5.4 DC gear motor (2)………………………………………………………..43
Fig.5.5 Stacker……………………………………………………………………45
Fig.5.6 Reclaimer…………………………………………………………………46

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 List of Tables
Table 2.1 Major differences between PLC and PAC…………………………………20

Table 3.1 PLC FBs-14MAR Specification ………………………………………….35

Table 5.1 Project component…………………………………………………………40

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 Problem Statement
This thesis is an industrial labor. My intent for this task is to build up a system (stacker reclaimer)
with PLC software that will do well for cement manufacture. The primary purpose of our task is
to hold in the Bucket wheel Excavator in the mining area. To control Boom, Total Structure - Slew
Left & Right Machine Movement - Forward & Reverse, Belt 1 & 2 - Start & Stop using With
PLC.

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 Chapter 1

Introduction

“When you can measure what you are talking about, and express it to numbers, you recognize

something about your subject. But if you cannot extent it, when you cannot definite it in numbers,
your knowledge is of an insufficient and unsatisfactory compassionate.” As cited by Lord Kelvin,
renowned for his oeuvre along the molecular motion who worked as a Scottish physicist and
mathematician from 1849-1899.
The sympathy of the properties and the handling qualities about heft material is an
essential necessity for most of the practicing engineers. Through those a long time there
has been a singular measure of development and literature dealing with
the basics of changing materials. Bulk Material taking care of will be founded on the invention of
Supplies utilized to those transportation of materials and consisting of machinery like conveyors,
stackers and reclaimers

1.2 Aim:

This thesis is an industrial labor. My intent for this task is to build up a system (stacker

reclaimer) with PLC software that will do well for cement manufacture. The primary purpose of
our task is to hold in the Can wheel excavator in the mining area. To control Boom, Downright
structure - slew exited & straight. Machine Movement - Forward & Reverse, Belt 1 & 2 - Start &
Stop using With PLC.

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1.3 Project Objectives:

The range of work for this labor is listed under;

 Define, describe and the functioning of the Stacker Reclaimer.
 From claiming mass materials handling and the characteristics of bulk fabric.
 Review of conveyor design and conveyor belts.
 Review of Stacker Reclaimer design, including control condition.
 Write a dissertation on the arrangement work.

1.4 Working of project:

Stackers and reclaimers are used in stockyards to stack inorganic, mineral, and other rough
raw Materials in piles, and then reallocate them for processing and cargo.

Fig 1.1 Stacker & Reclaimer

 Stackers are used to develop these large piles or circular stacks.

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  Reclaimers are used to gather and redistribute the stuff from the stacks or stacks of bulk
materials.

1.5 Types:

Thither are many dissimilar types of stackers and reclaimers. Examples include bucket stackers,

Circular stackers, and longitudinal stackers; redial reclaimers, bridge reclaimers, and portal
Reclaimer and combination or multi-use products

1.6 Applications:

Typically, stackers and reclaimers are used in:

 metallurgy and removal

 cement manufacture
 chemical construction
 power construction
 bulk material stations

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 Chapter 2

Literature Review

This chapter complicated the work of this project founded on different volumes, research papers

and internet. As our labor is based on automation, this topic mainly belongs to Industrial
automation. Starting time of all, this topic is belonging to introduction of automation and
its character. In the second part we discussed controllers for automation. Third part of
this subject belongs to selection criteria of choosing correct controller. The primary aim of this
chapter is becoming familiar with automation and control.

2.1 Introduction to Automation:

Society in its daily endeavors has become and then hooked on automation that it
is difficult to think of life without automation engineering. Automation covers a bit of unexpected
areas like trade, environmental protection technology, traffic engine, building engine. Arm and
medical. Emerge are the areas where automation is taking on a striking part.
Industrial automation engineers have a great deal of responsibility clinched alongside their calling.
They are said to produce such tasks which consume lesser time and increase efficiency of their
oeuvre which in result adopts the rapid acceleration of technological changes. Automation
increases the protection and efficiency of projects.

Types of Automation:
Automation of production systems can be separated into three basic types

 Fixed automation (Hard Automation)

 Programmable automation (Soft Automation)

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  Flexible automation.

Fixed Automation:

Fixed Mechanization alludes on the usage of special purpose equipment to automate

a set sequence of processing. Apiece of the operations in the succession is normally simple, taking a
plain linear or rotational movement or an uncomplicated combination of two. It
is comparatively difficult to suit alterations in the project plan. This is also called hard automation.

Programmable Automation:

With programmable automation, the project is designed with the capacity to alter the arrangement for

operations with suit different configurations. The process sequence is controlled by a program, which a
Set of orders coded. So that they can be read and executed by the system Programs can be qualified and
entered into the conception of a project to create fresh merchandise. This is also called soft automation

Flexible Automation:

Flexible automation is essentially an extension of programmable automation. A flexible automation

Framework may be skilled of creating a variety of pieces with nearly no time lost for changeovers from
one character style to the next. There is no damage in manufacture time while reprogramming the
system and changing the physical setup.

2.2 Automation Controllers:

PAC and PLC are automation controllers which are widely applied in industrial automation. We
used Programmable rationale controller (PLC) in our task. A brief presentation to these
controllers is discussed here to be familiar with these controllers of automation.

15
Programmable Automation Controllers:

Programmable automation checker (PAC) is a new name invented for native mechanization.
PAC is basically a box containing I/O including the central processing unit and
software. Actual CPU that is operating the scheme is built into I/0 system itself. A PAC mentions
to a controller that provides multi-correction control. For example, a PAC might offer
the power to carry out complex instructions as good as possessing integrated safety functionality.
PACs handle multiple projects simultaneously. Furthermore on controlling processes,
each independent reading and writing to system variable and devices a PAC might convey for
multiple customers.

Programmable Logic Controllers:

A programmable rationale controller is an advanced processer utilized for mechanization from

claiming electromechanical procedures, such as mastery of machinery on production line
gathering lines, delight rides, or light fixtures

PLCs are planned to various courses of action about advanced and analogue inputs furthermore
outputs, stretched out temperature ranges, protection to electrical clamor, and immunity to
vibration and shock. Plans to control machine operation are typically stored in non-instable
memory.

A PLC is an instance of a ''bard" real-time system since output results must be made in response
to input conditions within a limited time, otherwise unintentional operation will result. A brief
difference between PAC and PLC is described in Table 2.1.

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 Device PLC PAC

Processor Module 1 per rack Multiple processors per rack

Processor chips per module 1 microprocessor 2+high performance

Programming Ladder logic Structured text

Functionality Sequential scan of logic Dual scan of logic

Memory Up to 64K Up to 32000K

I/O 3000 128000

Table 2.1 Major differences between PLC and PAC

2.3 PLC Selection Criteria

Selecting the most appropriate controller for the provision relies once a number of elements. To choose
correct PLC for the application gives a proper direction to finish the project in time. The factors on which
PLC selection criteria depend are likewise portrayed previously following stages.

 Task requirements.
 Application requirements
 Communication requirements
 Software
 Size of computer storage
 Electrical requirements
 Physical environment.
 Number and nature of VO

 Required speed of CPU

 Speed of mental process.

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  Operator interface

Task Requirements:

Beginning point of solution for required task must understand that what is to be accomplished. The

program design assignment is broken down under a number of simple understandable elements. Each
element should be easily identified.

Application Requirements:
Enter what’s more yield units are required after determining the performance of system List the required
function and identify a specific type of gimmick. Find special operations for discrete, i.e. on/off logic and
then rundown the propelled capacities needed by basic discrete rationale.

Communication Requirements:

Some applications call for sending data outside of the procedure that is called communication.

Communication calls for sharing application Information or status with another electronic device, such
as a computer or a monitor in an operator's station or central control room Communication can take
place locally through a twisted-pair wire, or remotely via phone or radio modem mainly human and
machine interfacing HMJ and SCADA system requires data communication.

Electrical Requirements:
Main electrical requirements inputs, outputs Furthermore system power. Following three items
are considered while setting the electrical demands.

 Power t h o s e f r a m e w o r k e n t e r .
 Input device voltage.
 Output device voltage Also current.

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Physical Environment:

Reflect the surroundings where the restraint scheme is located physically. In harsh surroundings, house the

control system in a suitable enclosure. Remember to consider accessibility for maintenance,
troubleshooting or reprogramming.

Number and Nature I/O:

Determine the amount for inputs and outputs. In our laboratory prototype there are nineteen I/O. There
are six inputs and thirteen outputs. Further, nature of I/O should also be known if they need aid
advanced or analog, because each PLC contains separate ports for advanced furthermore simple I/O. In
our project, there are seven inputs and eleven outputs. All the I/O are digital

Speed of Operation:
Speed of operation must be experienced.
Determining the focal ratio, weigh these tips:

 Speed of process.
 If operations or events are "time critical" t h e y m u s t m a k e detected.
 In what time frame the fastest action must occur.

Operator Interface:

If the organization requires an operator control or interaction. In order to communicate information

about a machine or process status, or to permit an operator to input data, many applications require
operator interfaces. Old-style operator borders include pushbuttons, pilot lights and LED display.
Electronic operator interface devices display messages about machine status in descriptive text, display
part count and track alarms. Also, they can be utilized for information input.

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2.4 Advantages of Project:
Some Points of interest of this project are

 Low principal and operational cost

 Minimal care
 Simple connection
 Effortlessly re-locatable
 Easy to operate and recite
 Standard parts and workings (easily available)

2.5 Limitations of Project:

Each project need advantages as well as restrictions. Following points tell about the limitations of
this task.

 Primary investment is high

 Uses of chemical shampoos
 Scratches

Chapter 3

20
 Electrical Model

3.1 Relay:

A communicate is an electrically regulated switch. Many relays use an electromagnet to work a

swapping mechanism mechanically, but different operating rules are likewise applied. Relays are
used primarily where it is indispensable to hold a circuit by a low-power signal (with complete
electrical separation between control and regulated paths), or where different circuits must
be held by one signal. The primary relays were applied at long coldness telegraph circuits,
rehashing decimal the sign again and over advancing done from you quit offering on that one
circlet Furthermore retransmitting it to another.
Transfers were utilized mostly done phone exchanges what's more and initial computers
to perform logical operations.

A case of relay that can resist the high control obligatory to directly contain an electric motorized
or other piles is known as conductors. Solid-state relays control, power circuits having no
moving pieces; instead it employs a semiconductor gadget to do switching process. Relays with
standardized operating characteristics also frequently various working coils are employed to save
electrical circuits from. Overload or shut down; in modem electric force frameworks these

21
capacities are performed by digital instruments known as "protective relays".

Fig.3. 1 Omron relay

Basic Design:

A basic electromagnetic relay contains of a roll of wire enfolded around a soft iron core, an iron
yoke which uphold a low disinclination path for magnetic flux, a portable iron armature, and

22
person or that's only the tip of the iceberg sets of associates (there are two in the transfer
imagined as below). The armature will be indulged to the yoke and mechanically bonded to you
quit offering on that one alternately additional sets of moving contacts.
It is held in position by a coil thus that at the transfer will be de-eager the air gap is created in the
magnetic circle.

In this term, one of the two circles of contacts in the relay as shown below is closed, and the
other circle is opened. Different relays may have more or less sets of associates depending on
their drive. The relay in the pattern also has a wire linking the armature to the twosome.
This makes continuity of the circle between the moving contacts on the

Fig.3. 2 Operation of relay

Armature and the circuit track on the printed circuit board (PCB) through the brace, which is
soldered to the PCB. The coil is turned away, the armature is them back by a military
unit, roughly half as hard as the magnetic force, to its normal stance. Mainly this force
is supplied by a spring, but sobriety is also used commonly in industrial motor starters. Most
relays are constructed to function quickly. In a low-power application this decreases clamor; in a
high potential or present application it decreases arcing.

23
When the coil is thrilled with a direct current, a diode is set across the coil to remove the energy
from the failing magnetic field at deactivation, which would otherwise produce a power change
unsafe to semiconductor circuit components. Some automotive relays comprise a diode inside the
relay event. Alternatively, a contact protection network consisting of a Capacitor and resistor in
series known as "snubber circuit" that may suck up the rush.

If the coil is designed to be perked up by alternating current (AC), a small copper "shading ring"
can be appended to the final stage of the solenoid, making a small out-of-phase present which
increases the minimum pull on the armature during the AC series. A solid-state relay uses
a thyristor or other solid-state swapping device, operated by the switch signal, to switch the
measured load, or different of a solenoid. An Optocoupler (a light-emitting diode (LED) joined
with a photo transistor) can be applied to branch control and controlled circuits.

Types of Relay: Latching Relay:

A latching relay has two tranquil states (bistable). These are as well known as "instinct", "save",
or "break" relays. When the current is switched off, the relay runs in its terminal state. This
is taken with a solenoid operating a ratchet and cam device, or by taking in two opposite coils
with an over-center spring or enduring magnet to keep the armature and associates in place while
the coil is tranquil, or with a remainder core.

In the notch and cam example, the first beat to the coil goes the relay activated and the second
pulse goes it deactivated. In the case of two rolls, a pulse to one coil turns the relay activated and
a pulse to the opposite coil turns the relay deactivated. This type of relay has the benefit that one
coil takes power only for a prompt, while it is being changed, and the relay associates maintain
this setting crossways a power outage. A remainder core latching relay needs a current beat of
opposite schism to make it alteration state.

A stepping relay is a particular sort of multi-way latching relay factory-made for early automatic
telephone connections. An earth leak circuit wave provides and specify latching relay. Very early

24
computers may store bits in a magnetic latching relay, such as ferried or the later mired in
the loss switch. Some early processers used typical relays as a diversity of latch -- they
store numbers in the normal wire spring relays or reed relays by feeding an output wire spinal as
an input, designing in a Response loop or consecutive circuit.

Such an electrically-latching communicate needs continuous power to reservation state, unlike

magnetically latching transmits or motorized latching relays. In computer memories, latching
relays and other relays were placed by delay line memory, which in turn was invested in a
series of ever-faster and ever-smaller memory technologies relay.

Contactor Relay:

A contractor is very heavy-duty relay used for switching electric engines and lighting bundles,
although associates are not generally known as relays. Continuous current ratings for
specific servicers range from 10 amps to numerous hundred amperes. High-current associates are
manufactured with alloys covering silver. The undesirable arcing causes the contacts to oxidize;
however, silver oxide is primarily a good director. Such devices are principally applied for motor
starters. A motor starter is a contractor with overload protection devices added.

Contactor relays can be extremely loud to operate, making them unfit for use where noise is a
major worry. A contractor is an electrically controlled switch used for altering a power circuit,
similar to a relay excluding having advanced current scores. A contractor is activated by
a circle which delivers a much lower ability level than the switched circuit. Contactors come in
various patterns with varying capabilities and characteristics. Unlike a tour breaker, a declarer is
not specified to interrupt a short circuit current.

Contractor ranges from those throwing a breaking current of several amperes to thousands of

amperes and 24 V DC too many kilovolts DC. The physical size of contracts ranges from a device
close enough to nibble up with one hand, to large devices round about a meter (yard) on a side.

25
Contractors are generally utilized to contain electric engines, illumination, boiler, capacitor sets,
current evaporators, and other electrical lots.

Solid-state Relay:

A solid state relay (SSR) is a dense general electronic component that holds a similar time to an
electromechanical relay, but does not take in any touching parts, increasing long-term
dependability of the relay. Every solid-state expedient has a little drop in power across it. This
voltage drop reduces the amount of current to a given SSR can handle.
The minimum voltage drop for such a relay is a subprogram of the matter used to make
the gimmick. Solid-state relays valued to stand firm as much as 1,200 amperes have become
commercially obtainable.
Likened to electromagnetic relays, they may be rapidly triggered by transients.

Solid-state Contactor Relay:

A solid state contactor is a hefty-responsibility type of solid state relay, including the vital heat
sink, used where recurrent on/off cycles are necessary, such as with electronic heaters, small
electric engines, and lighting lots. There are no moving pieces to assume away and there is no
contact present due to shaking. They are ordered by AC control signs or DC control signs from
Programmable logic controller (PLCs), Transistor-transistor logic (TTL) bases, or other CPU.

Buchholz Relay:

A Buchholz relay is usually a care device checking the accumulation of gas in big oil-filled
modifiers, which will turn the alert along the slow accumulation of gas or shut down the
transformer if gas is developed at rapid interval in the transformer oil.

Overload Protection Relays:

26
Electric motors need overcurrent protection to minimize harm from over-charging the motor, or to
protect against short circuits in connecting lines or interior defects in the motorized windings. The
overload checking devices are a pattern of heat operated relay where a coil heats a bimetallic
strip, or where a solder pot melts, contracting a spring to operate auxiliary contacts. These
auxiliary contacts are present in series with the curl. If the overload sanities that excess current is
contemporary in the load, the coil is de-animated.

This thermal protection functions slowly, allowing the motor to income higher starting currents
before the defense relay will adjacent down. When the overload relay is bare to the same
environment as the motorized, a useful crude recompense for motor ambient temperature
is complete. The other main overload defense system utilizes an electromagnet coil in sequence
with the motorized circuit that directly alteration contacts. This is standardized to a control relay,
but requires a quite high fault present to operate the associates.

To prevent short over current flows from causing nuisance changing the armature movement
is weakened with a despot. The thermal and magnetic overload detections are conventionally
used in concert in a motor protection relay.

Electronic overload defense relays determine motor present and can check motor zigzagging
temperature using a "current model" of the motor armature scheme that can be set to offer more
dedicated motor protection. Some motor protection relays provide temperature detector inputs for
direct measurement from a thermocouple or resistance thermometer sensor added in the weaving

Pole and Throw:

Since relays are usually switches, the working practical to switches is also applied to relays; a
relay switch has one or more opposites, each of whose contacts can be turned on by invigorating
the coil in one of three ways:

27
Normally-Open (NO) associates connect the circle when the relay is turned on; the circuit is
turned off when the relay is still. It is too known as Form "A" contract or "make" contact. NO
contacts may also be specified as "early-build" or NOEM, which signifies that the contacts close
before the button or shift is fully joined.

Normally-Closed (NC) contacts disclose the circuit when the relay is activated; the circuit is
turned off when the relay is still. It is too known as Form B contact or "break" contact. NC
contacts may also be specified as "late-shift" or NCLB, which signifies that the
contacts remain closed until the button or shift is fully disconnected.

Change-Over (CO), or Double-Throw (DT), Contacts control two tours: one normally-open

interaction and other normally-closed interaction with a shared terminal. It is also known as a
Form C contact or "transfer" contact (break before work). If this type of contact uses "make
before break" functionality, and so it is known as a Form D contact.

The following assignments are usually used:

SPST - Single Pole Single Throw. These have two ends which can attach on or connect off. It
comprises two for the coil; such a relay has total four stations. It is vague whether the pole
is typically open (NO) or usually closed (NC). The language "SPNO" and "SPNC" is
sometimes practical to resolve the fault.

SPDT - Single Pole Double Throw . A common fatal attaches to one of the two others .It leases
in two for the helix, such a relay has total five terminals.

DPST - Double Pole Single Throw. These income in two different couples of ends. Like as two
SPST switches or relays actuated by a single scroll. It Include two for the helix. These relays have six
terminals in total. The poles can be Procedure A or Procedure B (or one of each).

DPDT - Double Pole Double Throw.

28
These take in two typical rows of changeover Termini. Like as two SPOT switches or relays
actuated by a single scroll. These relays have eight terminals, letting in the helix.

Fig 3.3 Different Types of Switches

The "S" or "D" can be supplanted with a number, determining multiple switches connected to a
single actuator. For example 4 PDT designates a four pole double throw relay having 12 stations.
EN 50005 are the appropriate standards for relay incurable totaling; a characteristic EN 50005-
compliant SPOT relay terminals should be numbered 11, 12, 14, Al and A2 for the C, NC, NO,
and spiral contacts correspondingly.

3.2 PLC (PROGRAMMABLE LOGIC CONTROLLER):

29
A Programmable Logic Controller, PLC or Programmable Controller is a numerical computer
made for automation of electromechanical procedures, such as robotic control of machinery on
factory assembly lines, amusement rides, or light fixtures. PLCs are widely practiced in many
industries and automobiles. Unlike general-purpose processers, the PLC is factory-made for
manifold inputs and production systems, various temperature ranges, immunity to electrical noise,
and immunity to vibration and shock.

Logic plans to control machine working are typically stored in backup battery or non-volatile
memory. A PLC is a stark model of a hard real time system since output results should be brought
forth in response to input conditions in a special time, the otherwise unexpected operation will result

Fig 3.4
PLC

Before the industrial of PLC, control, sequencing, and safety mesh logic for manufacturing
automobiles was mainly included of relays, cam regulators, barrel sequencers, and intensive
closed-loop supervisors. Since these might know in the hundreds. The procedure for renewing
such facilities for the yearly model changeover was very time exhausting and expensive, as
electricians needed to individually alter the cable relays to change the reason.

Digital processers, being general-purpose programmable plans, were soon devoted to control of
manufacturing operations. Early computers need specialist software engineers, and stringent
working ecological control for temperature, hygiene, and power excellence. Using a general-
purpose information processing system for control of process required, avoiding the computer from
the plant floor conditions.

30
An industrial control computer would have various characteristics: it would withstand the shop-
level environment; it would handle discrete (bit-pattern) input and end product in an effective,
extensible manner, it would not need years of training to use, and it would allow its operation to
be supervised. The time of response of whatever computer system must be quick enough to be
useful for control; the phenomenon of speed variation is according to the nature of the procedure.

In 1968 GM Hydra-Matic (the automatic broadcast division of General Engines) provides a

request for suggestions for an electronic change for hard-strengthened relay systems based on a
white tabloid written by a cause Edward R. Clark. The charming white broadside added up from
Bedford Associates of Bedford, Massachusetts. The primary PLC, chosen as 084 types because it
was the consequence of Bedford Associates eighty-fourth scheme.

Bedford Associates operated a new business devoted to developing, manufacturing, trading, and

marketing this new creation: Modicon, which is known as modular digital supervisor. One of the
people who functioned hard on that scheme was Dick Morley, who is known to be the "dad" of
the PLC.

The Modicon brand was traded in 1977 to Gould Electronics of US.A, and then vended to

German Company AEG and then through French Schneider Electric, the recent owner of this
PLC
Very primary 084 replicas built are now on show at Modicon's headquarters in North Andover,
Massachusetts, U.S.A. It was obtainable to Modicon by Over-all Manager; when the component
was withdrawn after about twenty years of continuous service. Modicon used the 84 moniker latest
of its product range until the 984 is manufactured. The automotive industry is still
the heaviest users of PLCs as a restraint device.

31
3.3 FATEK PLC:
The PLC being used in the project is an in-house developed by FATIK Corporations. The
specified model being used is FBs-24MAR of FATIK. The specs of this PLC have been keyed
out below.

Table 3.1: PLC FBs-24MAR Specification

32
Fig.3.5: F A T E K FBs-24MAR

33
 Chapter 4

I/O System

4.1 Programmable Logic Controllers:

Programmable Controller can be regarded in an industrial computer that bas a central

Processing and control unit, memory, inputs and output interface and a programming
Device Programmable Logic Controller (PLC) is the controller used in our project. We Used
FATIK plc for our project. This PLC has 14 inputs and 10 outputs. We used Ladder logic
language for controlling the process.

4.2 pin configuration of FATEK PLC:

Pin configuration of fatek plc is shown in figure 3.1. Here XO to X13 ports are inputs YO to
Y09 ports are outputs. GND stands for Ground and C0 to C6 are common Ports.

Figure 4.1 pin configuration of FATEK PLC

4.3 Inputs w.r.t. PLC:

34
In our system we have 12 inputs. All inputs are digital these inputs are fed into controller by
using push buttons and sensors. Input connections to the PLC are explained briefly in
following points.

PLC Input XO:

This input of PLC is used to start the process. There are many ways to start the process like
using sensor i.e. when system is detected by the sensor it gives signal to the PLC to drive first
conveyor. But we used push button to start the process because this is simplest method .On
pushing this button first conveyor starts running and carries the system to first station.

PLC Inputs X1 -X5:

These inputs of PLC are connected with motors. These motors connect with the system and
give their signal to PLC. Input X1 gives signal of system at first station

Where clean water is to be sprayed on vehicle. Similarly X2, X3, X4 and X5 are the input
signals of motors.

PLC Input X6:

X6 input of this PLC is used for emergency stop. This is basically a push button for the
purpose of emergency stop. When a malfunction is observed in the process this button stops all
the process and runs all conveyors for a specific time that is adjusted according to total time of
stacker reclaimer.

35
4.4 Outputs w.r.t PLC:

In our system we have 10 digital outputs. When inputs give a signal to PLC it performs some
action which is programmed by user. At output our system drives conveyor belts and motors.
These functions are perfumed in a sequence which is programmed on the bases of
inputs of the system Output connections are discussed in following points.

PLC Outputs YO-Y5:

On these output ports of PLC we have connected gear motors for driving conveyor belts. When
inputs comes from start button and PLC gives signal to switch gear motor of that stage.
When push button is pressed first conveyor which is connected to DC gear motor with belts
runs carrying system to first stage, similarly inputs give signals to PLC which turns on these
DC gear motors resulting running of conveyor belts. All these output ports are connected with
output components through relays.

PLC Output Y6:

On this port we have connected submersible pump to the system. This output ports gives
24VDC to relay which in return gives 220VAC to the system.

PLC Output Y1O:

On this port we have connected other motor. When input of this stage gives signal to PLC it
gives 24VDC to corresponding relay which switches motor

36
PLC Output YII:
On this port we have connected submersible pump to the system for travelling of the material.
This output port gives 24 VDC to relay which in return gives 220VAC to the system.

PLC Output Y12:

On this port of PLC we have connected DC motor. Basically this port is linked to relay which
switches these motors simultaneously. These fans are connected to the system (stacker
reclaimer).

37
 Chapter 4

Working Model

5.1 Project components:

The labor element is given under.

Materials ----------------

Conveyor belts 3

Motors 6

Relays 4

Boom 1

Bucket wheel 1

FATIK PLC 1

Table 5.1: project component

5.2 Steps of Working Model

Following are the stairs.

Materials
In our task we utilize materials for travelling through the system (stacker reclaimer). Such as
limestones, Sands and coals and so forth

38
 Figure 5.1 Limestones

5.2.2 Conveyor belt:

 A continuous moving band of cloth, rubber, or metal used for transferring objects from

one space to some other.
 A belt conveyor system consists of two or more blocks.
 In our task we use three conveyor belts.

Figure 5.2 Conveyor belts

39
Motors:
In our project we use 6 DC gear motors. A geared DC Electrically powered has a gear assembly
close to the engine. The fastness of the motor is reckoned in terms of rotations of the shaft per
minute and is termed as RPM. The gear assembly helps in increasing the torque and cutting
down the velocity. Practicing the right combination of gears in a gear engine, its haste can be scaled
down to any desirable shape. This idea where gears decrease the velocity of the machine,
but increase its rotation is recognized as gear reduction. This Vision will reconnoiter all
the small and major details that draw the gear skull and hence the rewarded of geared DC motor.

External Structure:
At the first view, the exterior structure of a DC geared engine looks as a conventional growth
over the simple DC ones.

Figure 5.3 DC gear motor (1)

40
The lateral position of the motor shows the outside swells of the gear dome. A nut
is positioned close the beam which helps in climbing on the motor to the other components of
the forum.

Figure 5.4 DC gear motor (2)

Likewise, an internally threaded hole is there on the beam to allow attachments or extensions such
as wheel to be bonded to the motor. 

41
Relays:

In our task we use four relays. An electrical device, typically incorporating an electromagnet,

which is actuated by a current or signal in one lap to spread or close another circuit. Here are two
simple animations illustrating how relays use one circuit to switch on a second tour.

When power runs through the first circuit (1), it sparks off the electromagnet (brown), generating
a magnetic domain (blue) that attracts a contact (red) and activates the second circuit (2). When
the power is switched off, a spring pulls the contact back up to its original spot, changing the
second circuit off again. This is an instance of a "normally open" (NO) relay: the contacts in the
second circuit are not linked by default, and switch on only when a current flows through
the attractor.

Other relays are "usually sealed" (NC; the contacts are associated so a current flow done them by
defaulting) and switch off just when the electromagnet is triggered, pulling or pushing the
contacts apart. Normally open relays are the most usual. Here's another animation showing how a
relay links two circuits together. It's basically the same thing drawn in
a somewhat different direction.

Along the odd side, there's an input circuit powered by a switch or a sensor of some sort. When

this loop is triggered, it provender current to an electromagnet that pulls a metallic switch closed
and triggers the second, output path (going on the good side). The relatively little current in the
input circuit, thus activates the larger current in the output circuit:

The input circuit (black loop) is switched off and no current movements through it pending
something (also a device before a switch departing) turns it on. The output circuit (blue loop) is
also switched away.

When a low current flow in the input circuit, it sparks off the electromagnet (shown here as a red
coil), which develops a magnetic line of business all round it.

42
Stacker:
Stacking function – Receiving bulk material from a yard conveyor and transport it to configured
storage pile patterns (e.g. Chevron, windrow and cone).

Figure 5 . 5 S t a c k e r

Reclaimer:

43
Reclaiming function – Recovering material from stockpiles and transfer it onto a yard conveyor
for further disbursement or use.

Figure 5.6 Reclaimer

 All functions can be checked remotely.

44
5.3 process

Stacker and Reclaimer are used in yards to stack crystals, rock, and other granulated raw
materials in piles, and then restructure them for handling and consignment. Stackers are used
to raise these large loads or rounded stacks. Reclaimer is used to gather and redistribute
the stuff from the stacks or stacks of bulk materials.

45
 Chapter 6

Conclusion and Future

6.1 Conclusions:

This report introduces the automation of Boom type, Bucket Wheel Stacker Reclaimer. The

automation is doe uses programmable logic controllers. PLC today are advanced in terms of
capability applicability. The program is written in ladder language using Fatek Win Polder
software. Fatek FBs-24MA sequence programmable controller is operated.

The wiring and installation process are also improved because the PLC input and output devices
are designated to specific addresses, and thus it further simplifies troubleshooting. PLC models
may be suggested depending on the need and specifications of different procedures. The control
system planned and trained for the project also explained in detail in the story.

The function of sensing elements, switches for using up the inputs and their execution is

also reported in detail.

The conveyor strap waged and construction has been clarified in detail. The H-Bridge circuit used
to drive the motors of conveyor belts and bucket wheel is also presented in detail. Our
implementation of cement stacking and reclaiming with Boom type, Bucket wheel Stacker
Reclaimer is efficient and precise.

46
6.2 Future Work:

 We can induce more efficient this system by using a SCADA system.

 A variety of detectors can be utilized with the aid of different sensor technology for fault
finding automatically in terms of alarms, indications and thus reducing human errors.
 Further research can be conducted to assess the efficiency losses in terms of price.

47
 Appendix A

Data Sheet of FATEK

48
 Appendix B

Specification of Relays

49
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51