KLNA-up

8/7/2019 KLNA-up

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TITLE OF PROBLEM: DESIGN & DEVELOPMENT OF SAFETY DOOR

CONTROLLER USING PLC

DURATION OF PROBLEM: 6 WEEKS

BASE SUBJECT: PLC & AUTOMATION

POSSIBLE INTEGRATION WITH THE FOLLOWING SUBJECT:

DIGITAL ELECTRONICS & SYSTEM

1. OUTCOMES

Knowledge

1. Design and develop a safety door

controller using PLC

2. Integrate the program with

hardware and software

3. Analyze and evaluate the performance of the system.

Process

1. Able to use programming software

to modify internal registers, perform

input/output tasks and compile

programming codes.

2. Able to conduct and control sensorsand actuators.

3. Able to simulate the programs built

with a simulation software and

determine the success of the

program

4. Able to design an algorithm on how

to solve the design problem.

2. PROFILE OF STUDENTS

Subject of Study: PLC & AUTOMATION

Year of Study: 3rd Year

Number of Students: 71

Nature of Groups: 5-6 students per group

3. PRIOR KNOWLEDGE & SKILLS

Digital Electronics, Ladder Programming, Sensors and Actuators.

Subject:

PLC & AUTOMATION

Subject Code:

PBL PROJECT ASSIGNMENT

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4. NEW INTEGRATED LEARNING ISSUES

1) Students able to design the algorithm and integrate the program with the hardware

2) Able to analyze and evaluate the performance of the system.

5. PROBLEM SCENARIO

GlaxoSmithKline (GSK) is one of the leading pharmaceutical companies in Malaysia.

GSK is a British based company producing healthcare, pharmaceutical and biological

products with strong reputation on research and development (R&D) of broad range of

pharmaceutical products covering anti infection, respiratory, metabolic, oncology and

vaccines. GSK has been operating in the country for more than 50 years and today

employs close to 600 people in its main facilities based in Ampang, Kuala Lumpur.

Due to the nature of the business, the company decides on employing a safety door intheir inventory facilities. Since there are many options available such as sectional up-

and-over type, non protruding type, retractable up-and-over and so on, the facility

manager decided to outsource the project to local company for design and assembly to

get the best deal.

As one of the bidding company, you are given the following restrictions in your design:

1. The door must have manual buttons on both side of the door (inside and outside)

as well as remote control button

2. The button should have the capability to stop the door midway and continue to

operate in another direction after the second push.

3. There should be mechanisms installed at each end of the door to prevent any

motion overdrive

4. Light beams must be installed across the bottom of the door. Any breakage when

the door closes will stop and reverse the motion of the door.

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5. Informational light should be installed and operates for some time after the door

opens or closes.

The facility manager requires full report on your design and you should be able to

produce a miniature prototype for the bidding.

6. FILA/KNL CHART

Facts/KnowledgeIdeas/Need to

KnowLearning Issues Action Plan

• PLC as main

controller

• Type of

door

• How to

build the

door?

• How to

integrate

components

?

•

• Week 8

Group setting &

Problem

Identification

• Week 9

Team discussion

& Self-directed

learning

• Week 10

Team discussion

& self-directedlearning

• Week 11

Synthesis &

Application

• Week 12

Synthesis &

Application

• Week 13Closure/Reflection

7. ASSESSMENT PLAN

Tool Individual/

Group

Formative/

Summative

Weightage Assessed by

Demo (rubric) Individual 5%

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Technical

Report/Log

Report (rubric)

Peer-to-peer review

Instructor

(rubric)

Group

Individual

13%

2%

8. FOLLOW-UP AFTER PROBLEM REVIEW

Action Taken:

Followed Up by:

9. PROBLEM-CRAFTING TEAM

Name:

1.

KLNA-up

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