AUTOMATIC CAR AC CONTROL SYSTEM USING PLC

A Project Report for Industrial Internship

In the partial fulfilment for the award of the degree of

DIPLOMA
In the

Department OF Electrical Engineering

FROM M.B.C. INSTITUTE OF ENGINEERING & TECHNOLOGY

at

Ardent Computech Pvt. Ltd.

CERTIFICATE FROM SUPERVISOR

This is to certify that student have successfully completed the project titled “ Automatic car AC Control
System Using PLC” under my supervision during the period from “9th NOVEMBER 2023” to “16th
NOVEMBER 2023” which is in partial fulfilment of requirements for the award of the DIPLOMA degree
and submitted to the Department of “Electrical Engineering” of “M.B.C. INSTITUTE OF ENGINEERING &
TECHNOLOGY”.
Name of Student Signature
1. TUSHAR SIKDAR
2. AZAD MUNSI
3. ARNAB CHAKRABORTY
4. CHINMOY GHOSH
5. NASIB MONDAL
6. ARINDAM GHOSH
7. ABHRADIP KUNDU
___________________________
Signature of the Supervisor
Date: 16th November 2023
Name of the Project Supervisor: SOUMYADIP SARKAR

ACKNOWLEDGEMENT

The achievement that is associated with the successful completion of any task would be
incomplete without mentioning the names of those people whose endless cooperation made it
possible. Their constant guidance and encouragement made all our efforts successful.

We take this opportunity to express our deep gratitude towards our project mentor,
[SOUMYADIP SARKAR] for giving such valuable suggestions, guidance and encouragement
during the development of this project work.

Last but not the least we are grateful to all the faculty members of Ardent Computech Pvt. Ltd.
for their support.

CONTENTS
• INTRODUCTION
• BASIC ELEMENTS
• PLC ARCHITECTURE
• INPUT/OUTPUT HARDWARE
• ADVANTAGE AND DISADVANTAGE OF PLC
• SOFTWARE IMPLEMENTATION
• OBJECTIVE
• LADDER LOGIC DIAGRAM (LAD)
• CONCLUTION

• INTRODUCTION TO PLC

Plc has become the most popular instrument for industries to control different
processes that is performing in the industry. It is an industry type computer that is
programmable for controlling functions. Due to its programmable capability
wiring control system been removed from industries like relays controlling. The
main advantage is its programming language is very simple there is no need to
use specific tools like other computer languages such as C, C++, etc. In coming
tutorial, we also learn about its programming language and its working. So let’s
get started with an introduction to PLC.
 AUTOMATION
• Automation is a set of technology that results in operation of machine and systems
without any significant human intervention and achieves performance superior to
manual operation.
• Automation is the creation of technology and its application in order to control and
monitor the production and delivery of various goods and services. It performs tasks
that were previously performed by humans. Automation is being used in number of
areas such as manufacturing, transport, utilities, defense, facilities, operations and
lately, information technology.
• Automation or industrial automation is the use of control systems such as computers,
controllers to control industrial machinery and processes, to optimize productivity in
the production of goods and delivery of services. Automation is a step beyond
mechanization. Whereas mechanization provides human operators with machinery to
assist them with the muscular requirements of work, automation greatly decreases
the need for human sensory and mental requirements.

AUTOMATION IMPACTS

• It increases productivity and reduce cost. It gives emphasis on flexibility and

convertibility of manufacturing process. Hence gives manufacturers the ability to easily
switch from manufacturing Product A to manufacturing product B without completely
rebuilt the existing system/product lines. Automation is now often applied primarily to
increase quality in the
manufacturing process, where automation can increase quality substantially.

• Increased consistency of output. Replacing humans in tasks done in dangerous

environments.
• Input/ Output Section: The input section or input module consists of devices like
sensors, switches, and many other real-world input sources. The input from the
sources is connected to the PLC through the input connector rails. The output
section or output module can be a motor or a solenoid or a lamp or a heater,
whose functioning is controlled by varying the input signals.
• CPU or Central Processing Unit: It is the brain of the PLC. It can be a hexagonal or
an octal microprocessor. It carries out all the processing related to the input
signals in order to control the output signals based on the control program.
• Programming Device: It is the platform where the program or the control logic is
written. It can be a laptop or a computer itself.
• Power Supply: It generally works on a power supply of about 24 V, used to power
input and output devices.
• Memory: The memory is divided into two parts- The data memory and the
program memory. The program information or the control logic is stored in the
user memory or the program memory from where the CPU fetches the program
instructions. The input and output signals and the timer and counter signals are
stored in the input and output external image memory respectively.

• PLC HARDWARE
 PLC hardware consists of several components:
1. Central Processing Unit (CPU): The brain of the PLC, responsible for executing the
control logic and processing data.
2. Input Modules: These modules receive signals from various sensors and devices in
the form of digital or analog inputs.
3. Output Modules: They control actuators, motors, and other devices based on the
processed information, providing outputs in the form of digital or analog signals.
4. Power Supply: Supplies power to the PLC system to operate the components.
5. Communication Ports: Interfaces that allow the PLC to communicate with other
devices or systems for data exchange.
6. Programming Interface: Software or hardware used to write, edit, and upload
programs to the PLC to define its behavior.
PLC hardware components vary depending on the manufacturer and the specific
requirements of the industrial application.
Understanding PLC hardware is crucial for designing, programming, and maintaining
automated systems effectively within industrial settings.
• INPUT/OUTPUT HARDWARE
• Toggle Switch:-
Toggle switches are versatile electromechanical switches operated by a lever or
baton that can be positioned into various states, thereby opening or closing a
circuit. Here's a breakdown of different types of toggle switches:

• SPST (Single Pole Single Throw): This type of toggle switch has a single input
and a single output, allowing for a single circuit to be opened or closed.
• SPDT (Single Pole Double Throw): SPDT switches have a single input and two
possible outputs. They can switch between two separate circuits or
connections.
• DPST (Double Pole Single Throw): DPST switches have two separate circuits
that are both either open or closed simultaneously when the switch is
activated.
• DPDT (Double Pole Double Throw): These switches have two inputs and two
outputs. They can control two separate circuits and have two possible
positions.
• SPCO (Single Pole Change Over or Single Pole, Double Throw): SPCO switches
have a single input and two possible outputs, enabling the switching between
two separate circuits or connections.
• QPDT (Quarter Pole Double Throw): This is a less common type of toggle
switch that provides multiple switching positions, typically more than two, by
breaking the circuit into quarters.

Each type of toggle switch offers unique functionalities and is used based on specific
circuit requirements in various applications, from electronic devices to industrial
machinery and beyond. The choice of toggle switch depends on the number of circuits
to control and the desired switching options.
 • Sensor:-
Sensor is a part of controlling circuit not a switch.
A sensor is a device that detects and responds to some type of input from the physical
environment. The specific input could be light, heat, motion, moisture, pressure, or any
one of a great number of other environmental phenomena.

Category of Sensor: -
1.Analog (Thermocouple, Thermistor, RTD). category
2.Digital (Inductive, Capacitive, Optical) category
1.Analog category-
A. Temperature
B. Humidity
C. Heart-Beat
D. Rain, Fog etc.
2.Digital category-
A. Inductive
B. Capacitive
C.IR(Infra-Red)
D. Optical

• ADVANTAGE OF PLC

• Reduced Space: PLCs are compact and solid-state devices, taking up less physical space
compared to traditional hard-wired controllers with electro-mechanical components.
• Higher Life and Reliability: PLCs are rugged and have fewer moving parts, making them
more durable and less prone to defects or damage, resulting in increased reliability and
longevity.
• Economical: Due to their reliability and lower maintenance needs, PLCs can be
considered a one-time investment. Their cost is recovered within a short period, making
them economically advantageous.
• Energy Saving: PLCs consume significantly less power compared to equivalent relay-
based controls, contributing to energy efficiency in industrial setups.
⦁ Ease of Maintenance:
1. Modular Replacement: Individual components in a PLC system can be easily replaced
if needed.
2. Easy Troubleshooting: PLCs offer simplified troubleshooting processes, reducing
downtime in case of issues.
3. Error Diagnostics: Programming units allow for easy identification and resolution of
errors.
⦁ Tremendous Flexibility: PLCs can perform various complex functions without the
need for rewiring. They can handle arithmetic operations, counting, time delays, etc.,
and offer high processing speed, flexibility in analog and digital processes, and the ability
to perform "On Line" or "Off Line" programming.
⦁ Shorter Project Time: Unlike hard-wired systems, PLC construction and wiring are
independent of control program definition. This allows for parallel work on control
programs and hardware, reducing project time.
⦁ Easier Storage, Archiving, and Documentation: PLCs are compatible with PC-AT,
printers, and floppy disks, simplifying storage, archiving, and documentation processes
related to control programs and data.
These advantages collectively make PLCs highly preferable in industrial automation due
to their compactness, reliability, cost-effectiveness, energy efficiency, ease of
maintenance, flexibility, and simplified project timelines and documentation.
• DISADVANTAGE OF PLC

⦁ Wiring Complexity: Connecting wires within a PLC system can be intricate and time-
consuming, especially in larger systems or when dealing with numerous inputs and
outputs.
⦁ Difficulty in Modifications or Replacements: Altering or replacing components in a
PLC setup may pose challenges, especially if the system design requires significant
changes. This can lead to downtime and increased complexity during upgrades or
modifications.
⦁ Complexity in Error Identification: Troubleshooting PLCs requires specialized skills.
Identifying errors or faults within the system can be challenging and might necessitate
experienced technicians or engineers, leading to increased maintenance time and costs.
⦁ Indefinite Hold-Up Time During Failures: When a problem arises within a PLC
system, the hold-up or downtime until the issue is resolved can be unpredictable and
sometimes lengthy. This unpredictability might affect production schedules and output.
These drawbacks highlight some of the limitations associated with PLCs,
particularly in terms of maintenance, troubleshooting, and system modifications.
However, advancements in technology and improved training for personnel
working with PLCs aim to address these challenges, aiming to streamline these
systems and reduce associated issues.

• SOFTWARE IMPLEMENTATION
• OBJECTIVE :- we are controlling Car door glass and AC in the car. Car door
glass can be controlled by any of the passenger or by the car driver. If individual
passenger wants to make the glass open and close he can do .If no passenger is
inside the car , driver can make all the door glass open and close from his seat.
When all the door glass closed then only AC can be started inside the car. If in
running condition of AC any door glass is opened by the passenger or driver then
Ac should gets OFF automatically.

• Ladder Logic Diagram (LAD)

• ALGORITHAM
Certainly! Here's an algorithm reflecting the described scenario:
```
Start:
Loop Forever:
If Start switch (Driver) D I0.0 is pressed:
Toggle Window W1 Q0.0 (if open, close; if closed, open)
If Switch (Passenger) P1 I0.1 is pressed:
Toggle Window W2 Q0.1 (if open, close; if closed, open)
If Switch (Passenger) P2 I0.2 is pressed:
Toggle Window W2 Q0.2 (if open, close; if closed, open)
If Switch (Passenger) P3 I0.3 is pressed:
Toggle Window W3 Q0.3 (if open, close; if closed, open)
If No Passenger:
If "EX1" I0.4 is active:
Control Window W1 Q0.0 (open/close)
If "EX2" I0.5 is active:
Control Window W2 Q0.1 (open/close)
If "EX3" I0.6 is active:
Control Window W3 Q0.2 (open/close)
If All Windows Closed (W1 Q0.0, W2 Q0.1, W3 Q0.2, W4 Q0.3):
If AC Switch ACSW I0.7 is pressed:
Turn on AC Q0.4
Else:
Turn off AC Q0.4 if any window opens (W1 Q0.0, W2 Q0.1, W3 Q0.2, W4
Q0.3)
```
This algorithm continuously monitors inputs from the driver and passengers,
controls the windows accordingly, and manages the AC system as per the
specified conditions. It toggles window states based on button presses and turns
the AC on or off based on window status. If any window is open, it automatically
turns off the AC system.

CONCLUSION
• I have achieved my project that is Automatic car AC Control System Using PLC.
• process using S7 300 PLC.
• This was successfully implemented.
• I consider this project as a journey where I acquired knowledge automation
industry.
• Also gained some insights into the subject which I have
shared in this report.