Automated Personal Shopping System Using Plc

7/30/2019 Automated Personal Shopping System Using Plc

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data transfer circuit is also included to permit data exchange between the home

data interface and the modem coupled to the host computer. The portable terminal

can be provided with unique identifying indicia so that the terminal can serve as a

form of identification for a user of the system. Database management of shopping

lists for multiple establishments, including customer preferences, can be

performed.

1.3 PROPOSED SYSTEM

In the Personal Shopping System provides customers PDA

which provides a friendly shopping interface and is monitored using SCADA. The

items and their quantity to be bought is given as input through SCADA and also

the whole grocery store is monitored by it. In order to reduce human effort,

SCADA is interfaced with PLC which makes the shopping cart move

automatically to the respective place and collect the required item. In case if the

item is not present and also if the item quantity is less than the prescribed quantity

an error signal will be shown by the SCADA so that the shop owner will load the

item in the respective shelf from where the error signal came.

1.3.1 Programmable Logic Controller

In order to automate the whole shopping process effectively

PLC is used. This is because with this the coding is done easily, when process

needs changes the coding can be changed easily.

1.3.2 SCADA

SCADA (supervisory control and data acquisition) is a type ofindustrial control system (ICS). Industrial control systems are computer controlled

systems that monitor and control industrial processes that exist in the physical

world. This project is used to monitor the whole shopping process and also to give

alarm if there is an error.


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CHAPTER 2

LITERATURE SURVEY

2.1 Sunil K. Timalsina, Rabin Bhusal, and Sangman MohNFC and itsApplication to Mobile Payment, Information Science and Digital

Content Technology, South Korea, 2012

NFC (Near Field Communication) is a recently emerging technology

for short range communications aimed to enhance existing near field technologies

such as RFID (Radio Frequency Identification). In this paper, NFC is introduced

in terms of the operation principles and compared with the existing short-range

communication technologies. The NFC enable mobile systems are more

technically discussed with respect to architecture and operating modes. Then, NFC

as a mobile payment solution is analyzed in terms of security and compared with

other existing mobile payment solutions by observing various metrics.

Fig 2.1 NFC and Its Application to Mobile Payment


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2.2 Ian Jenkins, John Pellaumail, Adam Petrovich, Thomas K. Roslak,

Jerome Swartz Personal shopping system portable terminal, USA, 2008

The present invention relates to a personal shopping system for combined

use in both the home of a user and a shopping establishment. The system includes

a host computer which is coupled to a host modem and, optionally, to at least one

wireless multi-access point. At least one shopping establishment kiosk cradle is

employed to interface with a portable terminal which is also part of the system.

The portable terminal can be used in both the shopping establishment and the home

of the user. It is configured to read bar codes associated with items related to

shopping, and includes a memory, a bar code reader, a wireless transceiver, and a

data interface. The data interface of the terminal communicates with a data

interface of the shopping establishment kiosk cradle. A home cradle for the

portable terminal is also provided and is adapted to remain in the home of the user.

It includes a home portable terminal-receiving station and a home data interface to

communicate with the data interface of the portable terminal. A home data transfer

circuit is also included to permit data exchange between the home data interface

and the modem coupled to the host computer. The portable terminal can be

provided with unique identifying indicia so that the terminal can serve as a form of

identification for a user of the system. Database management of shopping lists for

multiple establishments, including customer preferences, can be performed.


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2.3 Matsumori, Kunihiko Electronic shopping system having self-scanning

check and purchasing terminal, USA, 2009

An electronic shopping system, communicating between a store

computer and a customer assistance terminal, for providing item price information

for general customers and effecting item transactions for customers carrying a

valid customer identification indicia. The shopping assistance terminal operates as

a price check terminal in a default mode and is adaptively reconfigurable to a

transaction terminal mode upon receipt of a valid customer identification indicia. A

Price Look Up table is maintained in the store data base and, as a product is

scanned, the item's price is verified and displayed on an integral display screen. If

the terminal is configured in the transaction terminal mode, the item data is further

added to a transaction list maintained in a memory storage area of a customer ID

card.


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CHAPTER 3

HARDWARE DESCRIPTION

3.1 POWER SUPPLY UNIT

Fig 3.1 Power Supply Unit

3.1.1 Transformer

A transformer is a static electrical device that transfers energy by inductive

coupling between its winding circuits. A varying current in the primary winding

creates a varying magnetic flux in the transformer's core and thus a varying

magnetic flux through the secondary winding. This varying magnetic flux induces

a varying electromotive force (emf) or voltage in the secondary winding. The ratio

of the number of turns in the primary coil to the number of turns in the secondary

coil the turns ratio determines the ratio of the voltages in the two coils.

A step down transformer which we use in our project , is one whose

secondary voltage is less than its primary voltage. It is designed to reduce the

voltage from the primary winding to the secondary winding. This kind of

transformer steps down the voltage applied to it.


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The four diodes labelled D1 to D4 are arranged in "series pairs" with only

two diodes conducting current during each half cycle. During the positive half

cycle of the supply, diodes D1 and D2 conduct in series while diodes D3 and D4

are reverse biased and the current flows through the load as shown below.

Fig 3.2.1 The positive half cycle rectifier

During the negative half cycle of the supply, diodes D3 and D4 conduct in

series, but diodes D1 and D2switch "OFF" as they are now reverse biased. The

current flowing through the load is the same direction as before.

Fig 3.2.2 The negative half cycle rectifier

As the current flowing through the load is unidirectional, the voltage

developed across the load is also unidirectional.

Although one can use four individual power diodes to make a full wave

bridge rectifier, pre-made bridge rectifier components are available in a range of

different voltage and current sizes that can be soldered directly into a PCB circuit

board.


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3.1.3 Smoothing Capacitor (The Reservoir Capacitor)

For many applications, especially with single phase AC where the full-wave

bridge serves to convert an AC input into a DC output, the addition of a capacitor

may be desired because the bridge alone supplies an output of pulsed dc.

Fig 3.3 Smoothing Capacitor

The function of this capacitor, known as a reservoir capacitor (or smoothing

capacitor) is to lessen the variation in (or 'smooth') the rectified AC output voltage

waveform from the bridge. There is still some variation, known as "ripple". One

explanation of 'smoothing' is that the capacitor provides a low impedance path to

the AC component of the output, reducing the AC voltage across, and AC current

through, the resistive load. In less technical terms, any drop in the output voltage

and current of the bridge tends to be canceled by loss of charge in the capacitor.

This charge flows out as additional current through the load. Thus the change of

load current and voltage is reduced relative to what would occur without the

capacitor. Increases of voltage correspondingly store excess charge in the

capacitor, thus moderating the change in output voltage / current.

The simplified circuit shown has a well-deserved reputation for being

dangerous, because, in some applications, the capacitor can retain a lethal charge

after the AC power source is removed. If supplying a dangerous voltage, a

practical circuit should include a reliable way to discharge the capacitor safely. If


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the normal load cannot be guaranteed to perform this function, perhaps because it

can be disconnected, the circuit should include a bleeder resistor connected as

close as practical across the capacitor. This resistor should consume a current large

enough to discharge the capacitor in a reasonable time, but small enough to

minimize unnecessary power waste.

The capacitor and the load resistance have a typical time constant =

RCwhere CandR are the capacitance and load resistance respectively. As long as

the load resistor is large enough so that this time constant is much longer than the

time of one ripple cycle, the above configuration will produce a smoothed DC

voltage across the load.

When the capacitor is connected directly to the bridge, as shown, current

flows in only a small portion of each cycle, which may be undesirable. The

transformer and bridge diodes must be sized to withstand the current surge that

occurs when the power is turned on at the peak of the AC voltage and the capacitor

is fully discharged. Sometimes a small series resistor is included before the

capacitor to limit this current, though in most applications the power supply

transformer's resistance is already sufficient. Adding a resistor, or better yet, an

inductor, between the bridge and capacitor can ensure that current is drawn over a

large portion of each cycle and a large current surge does not occur.

The idealized waveforms shown above are seen for both voltage and

current when the load on the bridge is resistive. When the load includes

a smoothing capacitor, both the voltage and the current waveforms will be greatly

changed. While the voltage is smoothed, as described above, current will flow

through the bridge only voltage is smoothed, as described above, current will flow
http://en.wikipedia.org/w/index.php?title=Smoothing_capacitor&action=edit&redlink=1http://en.wikipedia.org/w/index.php?title=Smoothing_capacitor&action=edit&redlink=1


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faults; in modern electric power systems these functions are performed by digital

instruments still called "protective relays".

Fig 3.5 Relay Coil

A simple electromagnetic relay consists of a coil of wire wrapped around

a soft iron core, an iron yoke which provides a low reluctance path for magnetic

flux, a movable iron armature, and one or more sets of contacts (there are two in

the relay pictured). The armature is hinged to the yoke and mechanically linked to

one or more sets of moving contacts. It is held in place by a spring so that when the

relay is de-energized there is an air gap in the magnetic circuit. In this condition,

one of the two sets of contacts in the relay pictured is closed, and the other set is

open. A relay allows circuits to be switched by electrical equipment: for example, a

timer circuit with a relay could switch power at a preset time. For many years

relays were the standard method of controlling industrial electronic systems. A

number of relays could be used together to carry out complex functions (relay

logic). The principle of relay logic is based on relays which energize and de-
http://en.wikipedia.org/wiki/Relay_logichttp://en.wikipedia.org/wiki/Relay_logichttp://en.wikipedia.org/wiki/Relay_logichttp://en.wikipedia.org/wiki/Relay_logichttp://en.wikipedia.org/wiki/Relay_logic


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energize associated contacts. Relay logic is the predecessor ofladder logic, which

is commonly used in programmable logic controllers.

When an electric current is passed through the coil it generates a magnetic

field that activates the armature and the consequent movement of the movable

contact either makes or breaks (depending upon construction) a connection with a

fixed contact. If the set of contacts was closed when the relay was de-energized,

then the movement opens the contacts and breaks the connection, and vice versa if

the contacts were open. When the current to the coil is switched off, the armature is

returned by a force, approximately half as strong as the magnetic force, to its

relaxed position. Usually this force is provided by a spring, but gravity is also used

commonly in industrial motor starters. Most relays are manufactured to operate

quickly. In a low-voltage application this reduces noise; in a high voltage or

current application it reduces arcing.

The primary functions of a relay are:

The galvanic separation of the primary or actuating circuit and the loadcircuits

Single input/multiple output capability Separation of different load circuits for multi-pole relays Separation of AC and DC circuits Interface between electronic and power circuits Multiple switching functions, e.g. delay, signal conditioning Amplifier function.
http://en.wikipedia.org/wiki/Ladder_logichttp://en.wikipedia.org/wiki/Programmable_logic_controllerhttp://en.wikipedia.org/wiki/Programmable_logic_controllerhttp://en.wikipedia.org/wiki/Ladder_logic


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3.3 IR SENSOR

Infrared radiation is the portion of electromagnetic spectrum havingwavelengths longer than visible light wavelengths, but smaller than

microwaves, i.e., the region roughly from 0.75m to 1000m is the infrared

region. Infrared waves are invisible to human eyes. The wavelength region

of 0.75m to 3m is called near infrared, the region from 3m to 6m is

called mid infrared and the region higher than 6m is called far infrared.

Fig 3.6 IR Sensor The demarcations are not rigid , regions are defined differently by many.

Fig 3.6.1 Wavelength and Frequency distribution of rays


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Operation

When the Tx is forward biased, it begins emitting infra -red. Since its not invisible spectrum, one will not be able to see it through naked eyes but will

be able to view it through an ordinary cell phone camera.

The resistance R1 in the above circuit can vary. It should not be a very highvalue (~ 1Kohm) as then the current flowing through the diode would be

very less and hence the intensity of emitted IR would be lesser. By

increasing the current flowing in the circuit, one can increase the effective

distance of your IR sensor. However, there are drawbacks of reducing the

resistance. Firstly, it would increase the current consumption of your circuitand hence drain the battery (one of the few precious resources for any

embedded system) faster. Secondly, increasing the current might destroy the

Tx. So, the final choice should be a calculated trade-off between these

various factors.

Fig 3.6.2 Schematic of IR sensor


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One can also modulate the IR to achieve better distance and immunity.The receiver diode has a very high resistance, typically of the order of mega

ohms when IR is not incident upon it. However, when IR is incident upon

it,the resistance decreases sharply to the order of a few kilo Ohms or even

lesser. This feature forms the basis of using IR as a sensor. One will need to

connect a resistance of the order of a few mega Ohm in series with the Rx.

Fig 3.7 A Tx-Rx pair circuit.

Remember, the value of R2 can vary depending upon the Rx diode one isworking with. One is advised to first check the resistance of Rx diode with

no IR incident upon it and then select the value of R2 for decent

performance.

Case1: when no IR is incident upon the Rx Rx would be of the order of mega ohms and hence the output voltage would

be around 2.6V3V depending upon the choice of R2 and the Rx.

Case2: when IR is incident upon the Rx The resistance of Rx will sharply fall and hence the output voltage would be

around 1.8V - 1.5V depending upon the choice of Rx and R2.

Once a neat diagram between the output voltages in case1 and case 2 isobtained, sensor is ready.


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3.4 LIMIT SWITCH

Limit switch is one type Of " Contact Sensor" , In that there is normally

open Contact & Normally Close Contact, In limit switch there is plunger it is

directly Connected to NO & NC Contact if one press the plunger NO contact

become NC & NC contact become NO, the Working Principle same as contactor

( DOL starter ) main difference is in contactor There is Coil to attract the plunger

but In Limit Switch Plunger is Operated Mechanically Limit Switches is used

mainly for Safety Purpose & to take Feed-back for PLC in Automation industries.

Fig 3.8 Limit Switch

A limit switch is a switch, usually mechanical, that is actuated by a moving

part of some machine. Its operation is much like any other switch in that there are

contacts that move when a plunger or lever on the outside of the switch is pushed.

Internally there is an over center spring mechanism that snaps the switch open or

shut in response to a gradual motion of the plunger or lever.

Many limit switches have three terminals. One is the normally closed

contact, another the normally open contact , and the third is the common that

switches between these two as the mechanism is moved.


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Limit Switches Purpose

Limit switches, regardless of their final purpose, can only perform two

functions. The switches either activate (turn on) or deactivate (turn off) an

electrical circuit. Some of these switches are used in industry, and others are

utilized for common household appliances. Most limit switches that are used for

the home remain hidden from the user, so at times when something activates or

deactivates, it can be a mystery.

3.5 ULN 2803

A ULN2803 is an Integrated Circuit (IC) chip with a High Voltage/High

Current Darlington Transistor Array. It allows to interface TTL signals with higher

voltage/current loads. In English, the chip takes low level signals (TLL, CMOS,

PMOS, NMOS - which operate at low voltages and low currents) and acts as a

relay of sorts itself, switching on or off a higher level signal on the opposite side.

The ULN2803A is a high-voltage, high-current Darlington transistor array.

The device consists of eight NPN Darlington pairs that feature high-voltage

outputs with common-cathode clamp diodes for switching inductive loads. The

collector-current rating of each Darlington pair is 500mA. The Darlington pairs

may be connected in parallel for higher current capability.

A TTL signal operates from 0-5V, with everything between 0.0 and 0.8V

considered "low" or off, and 2.2 to 5.0V being considered "high" or on. The

maximum power available on a TTL signal depends on the type, but generally does

not exceed 25mW (~5mA @ 5V), so it is not useful for providing power to

something like a relay coil. Computers and other electronic devices frequently

generate TTL signals. On the output side the ULN2803 is generally rated at


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50V/500mA, so it can operate small loads directly. Alternatively, it is frequently

used to power the coil of one or more relays, which in turn allow even higher

voltages/currents to be controlled by the low level signal. In electrical terms, the

ULN2803 uses the low level (TTL) signal to switch on/turn off the higher

voltage/current signal on the output side.

The ULN2803 comes in an 18-pin IC configuration and includes eight (8)

transistors. Pins 1-8 receive the low level signals; pin 9 is grounded (for the low

level signal reference). Pin 10 is the common on the high side and would generally

be connected to the positive of the voltage you are applying to the relay coil. Pins

11-18 are the outputs (Pin 1 drives Pin 18, Pin 2 drives 17, etc.)

Applications include relay drivers, hammer drivers, lamp drivers, display

drivers (LED and gas discharge), line drivers, and logic buffers. The ULN2803A

has a 2.7k series base resistor for each Darlington pair for operation directly with

TTL or 5V CMOS devices.

Fig 3.9 ULN 2803 Specifications


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3.6 DC MOTOR

A DC motor is a mechanically commutated electric motor powered from

direct current (DC). The stator is stationary in space by definition and therefore its

current. The current in the rotor is switched by the commutator to also be

stationary in space. This is how the relative angle between the stator and rotor

magnetic flux is maintained near 90 degrees, which generates the maximum

torque.

DC motors have a rotating armature winding (winding in which a voltage

is induced) but non-rotating armature magnetic field and a static field winding

(winding that produce the main magnetic flux) or permanent magnet. Different

connections of the field and armature winding provide different inherent

speed/torque regulation characteristics. The speed of a DC motor can be controlled

by changing the voltage applied to the armature or by changing the field current.

The introduction of variable resistance in the armature circuit or field circuit

allowed speed control. Modern DC motors are often controlled by power

electronics systems called DC drives.

Fig 3.10 DC Motor


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3.6.1 10 RPM MOTOR SPECIFICATIONS

A 10 RPM, 12V DC motor was made use in the project for the

implementation of the tunnel safety exit assembly. A 10 RPM Centre Shaft

standard Series DC Motor is high quality low cost DC geared motor. It has steel

gears and pinions to ensure longer life and better wear and tear properties. The

gears are fixed on hardened steel spindles polished to a mirror finish. The output

shaft rotates in a plastic bushing. The whole assembly is covered with a plastic

ring. Gearbox is sealed and lubricated with lithium grease and require no

maintenance. The motor is screwed to the gear box from inside. Although motor

gives 10 RPM at 12V but motor runs smoothly from 4V to 12V and gives wide

range of RPM, and torque. Function of voltage and stall torque, stall current as a

function of voltage.

DC supply: 4 to 12V RPM: 10 at 12V Total length: 46mm Motor diameter: 36mm Motor length: 25mm Brush type: Precious metal Gear head diameter: 37mm Gear head length: 21mm Output shaft: Centered Gear assembly: Spur No-load current = 60mA(Max) Load current = 300mA(Max)


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3.7 CONVEYOR SYSTEM

Fig 3.11 Conveyor System

A conveyor system is a common piece of mechanical handling equipment

that moves materials from one location to another. Conveyors are especially useful

in applications involving the transportation of heavy or bulky materials. Conveyor

systems allow quick and efficient transportation for a wide variety of materials,

which makes them very popular in the material handling and packaging industries.

Many kinds of conveying systems are available, and are used according to the

various needs of different industries. There are chain conveyors (floor and

overhead) as well. Chain conveyors consist of enclosed tracks, I-Beam, towline,

power & free, and hand pushed trolleys.
http://en.wikipedia.org/wiki/Material_handlinghttp://en.wikipedia.org/wiki/Packaginghttp://en.wikipedia.org/wiki/Packaginghttp://en.wikipedia.org/wiki/Material_handling


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3.8 MOTOR USED TO ROTATE CONVEYOR BELT

Wiper motoris used to rotate the conveyor belt. A wiper motor is aDC motor with two permanent magnets that serves as a field for the motor,

arranged around the armature where the power is connected to the commentator of

the armature with two brushes, the armature is a set of electro-magnetic coils that

is each connected to its own two segments in the commentator so that the power is

connected to only one coil at a time to generate a magnetic field in the armature,

this field will oppose the field of the permanent magnet field, where the one field

will push the other away and make the motor to turn.

Fig 3.12 Wiper Motor


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3.9 DAMPER

The electromagnetic damper is a spring-loaded design that can be utilized

for a variety of purposes in the home or office. The principal of operation of an

electromagnetic damper involves a conductor moving in a non-uniform magnetic

field created by permanent magnets. The eddy currents induced in the conductor

produce a drag-force proportional to the speed. Electro-magnetic dampers also find

application in vibration isolation for structures, engine mounts for high

performance vehicles, force-feedback devices and industrial motion control. The

advantages of electro-magnetic damper is given below

Robust low cost design. Frictionless braking. High torque capability. No hydraulic fluid - no leaks. Passive device - no electrical or hydraulic control. Wide operating temperature range.

Fig 3.13 Damper


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3.10 PROGRAMMABLE LOGIC CONTROLLER

A digitally operating electronic apparatus which uses a programmable

memory for the internal storage of instructions for implementing specific functions

such as logic, sequencing, timing, counting, and arithmetic to control, through

digital or analog input/output modules, various types of machines or processes.

In essence, the programmable logic controller consists of computer

hardware, which is programmed to simulate the operation of the individual logic

and sequence elements that might be contained in a bank of relays, timers,

counters, and other hard-wired components. The PLC was introduced around 1969

largely as a result of specifications written by the General Motors Corporation. The

automotive industry had traditionally been a large buyer and user of

electromechanical relays to control transfer lines, mechanized production lines, and

other automated systems. In an effort to reduce the cost of new relays purchased

each year, GM prepared the specifications for a programmable logic controller in

1968. The requirements included:

The device must be programmable and re-programmable. It must be designed to operate in an industrial environment. It must accept 120V ac signals from standard pushbuttons and limit

switches.

Its outputs must be designed to switch and continuously operate loads suchas motors and relays of 2A rating.

Its price and installation cost must be competitive with relay and solid statelogic devices then in use.


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There are significant advantages in using a programmable logic controller

rather than conventional relays, timers, counters, and other hardware elements.

These advantages include:

Programming the PLC is easier than wiring the relay control panel. The PLC can be reprogrammed. Conventional controls must be rewired and

are often scrapped instead.

PLCs take less floor space then relay control panels. Maintenance of the PLC is easier, and reliability is greater. The PLC can be connected to the plant computer systems more easily than

relays can.

3.10.1 Schematic of PLC

A schematic diagram of a programmable logic controller is presented. The

basic components of the PLC are the following

Input module Output module Processor Memory Power supply Programming device


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Fig 3.14 Architecture Of PLC

The components are housed in a suitable cabinet designed for the industrial

environment. The input module and output module are the connections to the

industrial process that is to be controlled. The inputs to the controller are signals

from limit switches, pushbuttons, sensors, and other ON/OFF devices. Larger

PLCs are capable of accepting signals from analog devices of the type modelled.

The outputs from the controller are on/off signals to operate motors, valves, and

other devices required to actuate the process.

The processor is the central processing unit (CPU) of the programmable

controller. It executes the various logic and sequencing functions described in

previous Sections by operating on the PLC inputs to determine the appropriate

output signals. The processor is microprocessor very similar in its construction to

those used in personal computers and other data-processing equipment. Tied to the

CPU is the PLC memory, which contains the program of logic, sequencing, and

other input/output operations. The memory for a programmable logic controller is

specified in the same way as for a computer, and may range from 1k to over 48k of

storage capacity. A power supply of 115V ac is specially used to drive the PLC


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even though the components of the industrial process that are regulated may have a

higher voltage and power rating than the controller itself.

The PLC is programmed by means of a programming device. The

programming device (sometimes referred to as a programmer) is usually

detachable from the PLC cabinet so that it can be shared between different

controllers. Different PLC manufactures provide different devices, ranging from

simple teach pendant-type devices, similar to those used in robotics, to special PLC

programming keyboards and CRT displays.

3.10.2 Programming the PLC

Most of the programming methods in use today for PLCs are based on the

ladder logic diagram. This diagram has been found to be very convenient for shop

personnel who are familiar with circuit diagrams because it does not require them

to learn an entirely new programming language. What is required is a means of

inputting the program into the PLC memory:

There are various approaches for entering and interconnecting the individual logic

elements. These include:

1. Entry of the ladder logic diagram

2. Low-level computer-type languages

3. High-level computer-type languages

4. Functional blocks

5. Sequential function chart


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Fig 3.15 PLC

3.11 RS232 SERIAL PORT CONNECTOR PIN LAYOUT :

RS-232 is a serial communications standard that provides asynchronous andsynchronous communication capabilities, such as hardware flow control,

software flow control, and parity check. It has been widely used for decades.

Almost all gears, instruments with digital control interface, andcommunications devices are equipped with the RS-232 interface. The typical

transmission speed of an RS-232 connection is 9600 bps over a maximum

distance of 15 meters.

The male sockets are used on the DTE (Data Terminal Equipment ) or PCside. The female sockets are on the DCE (Data Communication Equipment )

or Modem Side.


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3.11.1 9 Pin connector (DB-9)

Serial

No.

Pin Description

1 DCD Data Carrier Detect

2 RD Received Data

3 TD Transmitted Data

4 DTR Data Terminal Ready

5 GND Signal Ground

6 DSR Data Set Ready

7 RTS Request To Send

8 CTS Clear To Send

9 RI Ring Indicator

Table 3.1 9 pin connector description

Fig 3.16 RS232 Cable


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9 Pin 25 Pin Pin Description

3 2 TX Transmit Data

2 3 RX Receive Data

7 4 RTS Request To Send

8 5 CTS Clear To Send

6 6 DSR Data Set Ready

5 7 GND Signal Ground

1 8 DCD Data Carrier Detect

4 20 DTR Data Terminal

Ready

9 22 RI Ring Indicator

Table 3.2 Pin configuration Of RS232 port

Transmit Data, the pin from which data is sent to the device connected tothe port.

Receive Data, the pin in to which data is sent from the device connected tothe port.

Request To Send, the pin on which the port requests that it wishes totransmit data to the device connected to the port.

Clear To Send, the pin on which the device connected to the port grantspermission to the port to transmit it's data.

Data Set Ready, the pin on which the device connected to the port states ithas data for the port.

Data Terminal Ready, the pin on which the port states it is ready to receivedata from the device connected to the port.


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Data Carrier Detect, this pin is used only by modems stating the modemlink is ready to transfer data (and should be held at 'on' if not used).

Signal Ground, this pin is probably the most important. It is the pin towhich all signals are referenced as well as carrying the return current of any

signal.

The original pin layout for RS232 was developed for a 25 pins D sub

connector. In this pin-out provisions were made for a secondary communication

channel. In practice, only one communication channel with accompanying

handshaking is present. For that reason the smaller 9 pin version is more

commonly used today


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EXAMPLE :

Fig 4.1 Example of SCADA process

4.2 WONDERWARE INTOUCH 10.1

Wonderware InTouch 10.1 is the quickest and easiest way to create human-

machine interface (HMI) applications. InTouch is a component of the Wonderware

Factory Suite. InTouch applications span the globe in a multitude of vertical

markets including food processing, semiconductors, oil and gas, automotive,

chemical, pharmaceutical, pulp and paper, transportation, utilities, and more.

By using InTouch, one can create powerful, full-featured applications thatexploit the key features of Microsoft Windows, including ActiveX controls, OLE,

graphics, networking and more. InTouch can also be extended by adding custom

ActiveX controls, wizards, generic objects, and creating InTouch Quick Script

extensions.


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4.2.1 To create a new application

On the File menu, click New, or click the New tool in the toolbar. TheCreate New Application wizard appears.

Click Next. A second Create New Application wizard appears. By default,the system will display the path to the InTouch directory followed by "New

App."

In the input box, type the path to the directory in which the application hasto be created or click Browse to locate the directory.

Click Next. If the directory specified does not exist, a message dialog boxappears asking to create a new one. Click OK. A third Create New

Application wizard dialog box appears.

Fig 4.2 Create a New Application Window

In the Name box, type a unique name for the new application's icon thatappears when the application is listed in the InTouch Application Manager

window.


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In the Description box, type a description of the application.4.2.2 Working with Wizards

Wizards save a considerable amount of time during application

development. They are easy to use and easy to configure. To configure a wizard,

you install it, select it in the Wizard Selection dialog box, paste it into your

window and then double-click it. Its respective configuration dialog box appears (if

it is a wizard that can be configured).For example, if one wants to use a slider

wizard, one would need to configure items such as the tag name effect, the

minimum and maximum range labels for the slider, the fill color, and so on. Onecan save a considerable amount of development time by using Wizards because

one don't have to draw the individual components for the object, or set the value

ranges for the object, or animate the object.

The FactorySuite InControl program includes the following five wizards that

one can place in an InTouch window. These wizards allow easy and effective

interaction between InControl and InTouch

4.2.3 To place a wizard in a window

Click the Wizard Dialog tool in the Wizards/ActiveX Toolbar. The WizardSelection dialog box appears.

In the list of wizards, click the category of wizards that you want to use. Allavailable wizards in that category will be shown the display area. For

example, if one selects Buttons ,all available button wizards will

immediately be shown in the display area.


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Select the wizard that is to be used and then click OK or double-click thewizard. The dialog box will close and the window reappears.

The cursor will change to a corner symbol when one returns to the window. Click the location in the window where one wants to paste. Double-click the wizard to configure it (if applicable)

Fig 4.3 Wizard Selection

Animation Link Selection Dialog Box: One can define multiple links forthe objects or symbols. By combining various links, one can create almost

any screen animation effect imaginable.One can make objects change

colour, size, location, visibility, fill level, and so on.

4.2.4 Creating Slider Touch Links

Slider Touch Links are usedto create objects or symbols that can be moved

around the window with the mouse or other pointing devices such as a finger on a

touch screen. As the object or symbol is moved, it alters the value of the tagname


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linked to it. This provides the ability to create devices for setting values in the

system.

An object may have a horizontal or a vertical slider touch link, or both. By

using both the links on a single object, the value of two analog tag names can be

altered simultaneously.

4.2.5 To create a horizontal (or vertical) slider link

Fig 4.4 Slider Selection (Animation Link)

Double-click the object or select it and then, on the Special menu, clickAnimation Links. The link selection dialog box appears.

In the Slidersection, click Horizontal. The Horizontal Sliderdialog boxappears.

In the Tagname box, type an analog (integer or real) type tagname. In the At Left Endbox, type the value for the tagname when the slider is in

its farthest left position.


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In the At Right Endbox, type the value for the tagname when the slider is inits farthest right position.

In the To Leftbox, type the number of pixels the slider can move to the left. In the To Rightbox, type the number of pixels the slider can move to the

right.

Select the Reference Locationon the object that the cursor will lock on formoving the object.

Click OK to attach the link to the object and return to the animation linksdialog box. One can now attach another link to the object if desired.

4.2.6 Window scripts

Window Scripts are linked to a specific window. There are three types of scripts

that can be applied to a window.

Fig 4.5 Input signal selection window


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4.2.6.1 Window Script Description

On ShowExecutes one time when the window is initially shown. While Showing Executes continuously at the specified frequency while the

window is showing.

On HideExecutes one time when the window is hidden.4.2.6.2 To create windows script

On the Specialmenu, point to Scripts, and then click Window Scripts. The

Window Scripteditor appears.

Fig 4.6 Window Script Editor

When one selects While Showing, the Every 0 Millisecondsbox becomesactive. In the box, type the number of milliseconds that wanted to elapse before the

script executes. If one wants the script to execute immediately, create an identical

On Showscript. However, as long as the condition or event for the While showing

script is met, the script will repeatedly execute at the specified frequency.


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4.3 WONDERWARE OMRON HOST LINK SERVER:

Introduction

The Wonderware OMRON Host Link I/O Server (referred to as the

server through the remainder of this Users Guide) is a Microsoft Windows

application that acts as a communications protocol server. It allows other Windows

application programs access to data from OMRON PLCs (also referred to as

devices) using the Host Link protocol. The OMRON Host Link I/O Server

communicates with OMRON E5AX, E5AF, and E5EF Fuzzy Temperature

Controllers, C-Series, and CV-Series PLCs, K3TS, K3TH, K3TR, and K3TX

Intelligent Signal Processors and the ES100 Digital Controller/ Programmer via

serial RS-232/RS-422/RS-485 lines. While the server is primarily intended for use

with Wonderware InTouch, it may be used by any Microsoft Windows program

capable of acting as a DDE, FastDDE, or SuiteLink client.

Accessing Remote Items via the I/O Server

The communications protocol addresses an element of data in a conversationthat uses a three-part naming convention that includes the application name,topic

name, and item name. The following briefly describes each portion of this naming

convention:

Applicationname:The name of the Windows program (server) that will beaccessing the data element. In the case of data coming from or going to

OMRON equipment via this server, the application portion of the address is

OMRONHL.

Topic name: Meaningful names are configured in the server to identifyspecific devices. These names are then used as the topic name in all

conversations to that device. For example, HLPLC.


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Item name:A specific data element within the specified topic. For example,when using this server, an item can be a relay, timer, counter, register, and

so on, in the PLC.

Connecting the Computer to the Host Link

The following diagrams illustrate the cable pin outs required to connect the

various OMRON devices to the host computer via RS-232 application name.The

name of the Windows program (server) that will be accessing the data element.

Configuring the I/O Server

Once the server has been installed, a small amount of configuration is

required. Configuring the server automatically creates a configuration file named,OMRONHL.CFG. This file stores the configuration information for the adapter

cards or communications ports and all of the topic definitions. The configuration

file is automatically saved to the directory in which the server is installed, unless a

different directory is specified.

4.3.1 To perform the required configurations

Start up the server by double-clicking on its icon. If the server starts up asan icon, double-click on the icon to open the server's window.

Fig 4.8 OMRON host link. To access the options used for the various configurations, open the

Configuremenu.


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Fig 4.9 OMRON host link configure menu

4.3.2 Configuring a Communications Port

To configure the communications ports that will be used to communicate

with the OMRON device:

From the Configuremenu, select Communication Port Settings. When this option is selected, the Communication Port Settingsdialog box

will appear.

Fig 4.10 OMRON communication port settings

4.3.3 Communications Port Settings

To configure communications port settings

Select a communications port connected to the OMRON device from theComPortdrop-down box.


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In the Reply Timeoutbox, enter the amount of time (in seconds) that allPLCs connected via this communications port will be given to reply to

commands from the server.

From those listed in the Baud Ratebox, select the baud rate (serial bitrate) setting that matches the configuration of the OMRON device

From the Data Bitsbox, select the number of data bits that matches theconfiguration of the OMRON device.

Select the number of stop bits that matches the configuration of theOMRON device from those listed in the Stop Bitsbox.

In the Paritybox, select the parity setting that matches the configurationof the OMRON device.

Click Defaultsto reset the settings to their default values without savingChanges .

Click Saveto save settings for the selected COM Port.


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The dialog box will remain displayed, giving the option to configureadditional COM Ports

Click Doneto close the dialog box. If the settings have not been saved, the following dialog box appears:

Click Yesto save settings for the COM Port. Click Noto prevent the settings from being saved. Click Cancelto return to the Communication Port Settingsdialog box

without saving the settings.

4.4 CX PROGRAMMER:

The information within a CX-Programmer project consists of ladder

program(s),operands, required PLC memory contents, IO tables, expansion

instructions (if applicable) and symbols. Each CX-Programmer project file is

separate and is a singledocument.CX-Programmer can only open a single project at

a time. However, it is possible to deal with many project files by using CX-

Programmer at once.

A CX- Programmer project has a .CXP or .CXT file extension. (normally

the .CXP file is used, and is a compressed version of the .CXT file).Once the

project itself is created the desired PLC and symbol information can be defined.


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Fig 4.11 CX programmer window

4.4.1 DIAGRAM WORKSPACE

The Diagram Workspace can display a Ladder program, the symbol table of

that program or the Mnemonics view. The details displayed depend upon the

selection made in the project workspace. When a new project is created or a new

PLC added to a project, an empty Ladder program is automatically displayed on

the right-hand side to the project workspace. The symbol table and Mnemonics

view must be explicitly selected to be displayed. All views can be opened at thesame time and can be selected via options associated with the Window menu. The

Ladder program graphically represents the PLC power flow from left to right and

the program sequence from top to bottom. PLC program instructions can be

entered as a graphical representation in Ladder form. Programs can be created,


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edited and monitored in this view. Follow the examples provided to develop an

understanding of the Diagram Workspace. Select the View Diagram button from

the toolbar. The Ladder program window is displayed in the Diagram Workspace.

The following items are standard features of the Ladder program area:

Cursor: A rectangular block showing the current position within the rung.The location of the cursor is displayed in the status bar.

Rung: A logical unit of a ladder program. A rung can encompass one ormore rows and columns. All rungs are numbered.

Bus-bars: The left bus-bar provides a graphical representation of the powersupply bus-bar. The right bus-bar contains the output region: to align

objects to the right bus-bar. The right bus-bar is selectable for display. If

shown, the ladder rungs are justified so that the outputs of the rungs are

organized along it.

Grid Dots: Dots that display at the connection points of each cell. Todisplay the grid, select the Grid button from the toolbar.

Rung Margin Area: The area to the left of the Left bus-bar. The rungnumber and step number for each rung are shown here (rung number on the

left).

Automatic Error Detection: A bar is displayed to the left of the currentlyselected rung area. As elements and instructions are added to the rung, the

additions are automatically checked to see if they are valid. The color of the

bar indicates the validity of the program: red highlights an error, while

green indicates a correct entry. In addition, elements of the text on the

ladder are drawn in this error color if a problem exists. The color and

display preferences of the above features can be amended by selecting

Options from the Tools menu. More than one element in a rung can be


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selected by pressing the mouse button down on an element and, keeping the

left-mouse button depressed, dragging a highlight over other elements in the

rung. Selected elements can then be moved as a block.

Fig 4.12 section window


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EXAMPLE :

Fig 4.13 Example program


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CHAPTER 5

PROJECT DESCRIPTION

5.1 AUTOMATED PERSONAL SHOPPING SYSTEM USING PLC ANDSCADA BLOCK DIAGRAM

Fig 5.1 Block diagram

5.1.1 Operation

5.1.1.1 Inputs to PLC

The table 5.1 shows the input sensors used in the process. These

sensors senses the input and gives it to the driver circuit. All the inputs are digital

inputs.

The IR pairs ( IR1,IR2,IR3) are used to sense whether shopping cart reaches

the position so that the items are dropped into the cart perfectly. These are called as

Position sensors.


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the driver circuit is zero i.e LOGIC 0.Negative switching is mainly used because if

the output from the driver circuit is positive voltage with less amplitude then

switching doesnt takes place perfectly so in these cases, taking a point to ground

for switching is used.

5.1.1.3 Relay

A relay is an electrically operated switch. Many relays use an electromagnet

to operate a switching mechanism mechanically, but other operating principles are

also used. Relays are used where it is necessary to control a circuit by a low-power

signal (with complete electrical isolation between control and controlled circuits),

or where several circuits must be controlled by one signal.

5.1.1.4 Output from PLC

As soon as the process is started conveyor motor(CM) starts running and

when the cart reaches the position the component motors(M1M2,M3) pushes the

required number of items inside the cart. The function of the dampers(D1,D2,D3)

is to hold the cart in the correct position until the items are dropped into it.

5.2 PROGRAMMING

The programming part initially involves selecting the list of inputs

and outputs(i/o) list . In this project there are 8 digital inputs and 10 digital

outputs. The purpose of having manual mode is to check if all the mechanical

components are in order and working correctly . After checking the whole process

in manual mode the plc is made to operate in auto mode with real time inputs.


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Table 5.2 Digital outputs from PLC


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CHAPTER 6

RESULTS AND DISCUSSION

In this project there are about three jobs corresponding to three differentitems in the supermarket. As soon as the customer selects his/her required items

and corresponding quantity the same will be processed in the automated manner. A

unique customer id will be provided to each and every customer to avoid confusion

and the same will be displayed on the cart so that the customer can identify his job

in an effortless manner.

For the purpose of easy billing NFC smart Tags are used along with acreation of smartphone application, the application will display the list of available

items in the supermarket along with their quantity and this allows the customer to

select the items he/she requires and the total billing amount will be calculated and

the same will be deducted from their account.

The very fact in using NFC technology is that its more secure compared t o

all the other wireless access mechanisms because range of NFC is of the order of

say ten centimeters.

The SCADA acts as an interface between user and the process and the

customer name and other credentials will be displayed in an GUI such as LED,

LCD televisions for hassle free service.

Automating the entire shop is a one time investment and since human

intervention is completely reduced and the efficiency is very much higher.


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Fig 6.1 Working model

The working model of the project is shown above and as mentioned

previously there are three jobs namely a circular job, rectangular job and a hanging

job. The entire process is automated using PLC and input to the PLC is five set of

IR pairs and three limit switches. The purpose of the limit switch is to count the no

of objects and one revolution corresponds to one object.

The output from the PLC is used to control seven motors and three dampers.

since conveyor motor is always ON the tray has to be stopped at the appropriate

location that is after IR senses the tray and for this process dampers are being used.


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If in case the item is low in quantity or if no items are available IR pair

senses it and sends an error signal which is displayed on the SCADA screen and so

that items can be reloaded in the appropriate location.

The entire switching of devices is done by negative switching technique

using ULN 2803 so that no damage is done to any of the circuits are components.

A 2A transformer is being used to provide 12v DC for all motors and a 1A

transformer is used to power all transmitter and receiver circuits.

The damper is a bi-directional type and requires both positive and negative

12V DC for operation.

Fig 6.2 Working model of hanging job


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Fig 6.3 Development mode of SCADA

In the development mode using Intouch wonderware software the menu for

operating the entire unit is done. The shopping code is an unique code provided to

each and every customer and the same is being displayed on the GUI.

As soon as the customer enters his/her requirement in each of the separate

item the same quantity is displayed in the require column. Auto Process initiates

the conveyer set up and the entire process follows.

The unit price per quantity is displayed in the Unit Price column and as per

the user requirement and amount for multiple quantities is being summed up and

the total billing amount is displayed in the Total column.

As soon as the conveyor motor is switched ON the conveyor button

indicates it and if any case any item is lower in number the empty sensor senses it

and the same is displayed in empty button.


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CHAPTER 7

FUTURE SCOPE AND CONCLUSION

The future work involves the usage of NFC smart tags wherein the user

information along with the other credentials are stored. An android based

application is created regarding the list of items present in the store. The customer

selects the list of items that he/she wants to purchase and just waives the

smartphone near the NFC receiver, a shopping id is created pertaining to each of

the individual and the same will be displayed on the shopping cart which collects

the items. After the collecting process has been completed the total amount will be

calculated and the same amount will be deduced from his/her account.

Fig 7.1 Architecture of future work using NFC

Fig 7.2 NFC Smart Tags


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REFERENCES

1. http://cospa.ru/PLC/CP1E/W461/E1/02 CP1E Introduction Manual.pdf

2. http://www.ia.omron.com/product/21.html

3. http://www.keyence.com/products/plc/plc/kv/kv.php

4. http://www.omron.co.in/programmablecontrollers/cpie

5. Ian Jenkins, John Pellaumail, Adam Petrovich, Thomas K. Roslak,

Jerome Swartz Personal shopping system portable terminal, USA, 2008

6. Kevin Collins, PLC Programming for Industrial Automation.

7. Matsumori, Kunihiko Electronic shopping system having self-scanning check

and purchasing terminal, USA, 2009.

8. Sunil K. Timalsina, Rabin Bhusal, and Sangman Moh NFC and its

Application to Mobile Payment, Information Science and Digital Content

Technology, South Korea, 2012.

9. Stuart A. Boyer, Supervisory Control And Data Acquisition.
http://cospa.ru/PLC/CP1E/W461/E1/02%20CP1E%20Introduction%20Manual.pdfhttp://www.ia.omron.com/product/21.htmlhttp://www.keyence.com/products/plc/plc/kv/kv.phphttp://www.omron.co.in/programmablecontrollers/cpiehttp://www.omron.co.in/programmablecontrollers/cpiehttp://www.keyence.com/products/plc/plc/kv/kv.phphttp://www.ia.omron.com/product/21.htmlhttp://cospa.ru/PLC/CP1E/W461/E1/02%20CP1E%20Introduction%20Manual.pdf

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