Week 9 - Proposal Presentation

 For this week, Sir Zaki was given to us for researching on startup of the technology machine. This technology machine needs to improve from a Programmable Logic Controller to a microcontroller. The microcontroller would combine with the sensor, Internet of Things (IoT), machine learning or Artificial Intelligence into the project.

            A Programmable Logic Controller, or PLC, is a ruggedized computer used for industrial automation. These controllers can automate a specific process, machine function, or even an entire production line. The PLC receives information from connected sensors or input devices, processes the data, and triggers outputs based on pre-programmed parameters.
Depending on the inputs and outputs, a PLC can monitor and record run-time data such as machine productivity or operating temperature, automatically start and stop processes, generate alarms if a machine malfunctions, and more. Programmable Logic Controllers are a flexible and robust control solution, adaptable to almost any application.

            PLC control system is that it regards PLC as a control key component, utilize special I/O module to form hardware of control system with a small amount of measurement and peripheral circuit, to realize control to the whole system through programming.


1.      High Reliability

Strong anti-interference quality and very high reliability are the most important features of PLC. To make PLC work stably in strong interferential circumstances. Many techniques are applied in PLC. Software control instead of relay control mode can decrease faults that are brought about by the original electric contact spot outside working badly. Industrial-grade components made by advanced processing technology can resist interference, and self-diagnosis measures of watchdog circuits for protecting memory can improve the performance of PLC greatly.

 

2.      Good Flexibility

There are several programming languages for PLC including ladder diagram, SFC, STL, ST, and so on. If the operator can master only one of the programming languages, he can operate PLC well. Every who wants to use PLC has a good choice. Based on engineering practice, capacity and function can be expanded by expanding the number of modules, so PLC has good flexibility.

 

3.      Quality of Strong Easy-Operating

It is very easy to edit and modify programs for PLC by computer offline or online. It is very easy to find out where the fault lies by displaying the information of fault and function of Self Diagnosing Function, and all these make maintenance and repair for PLC easier. It is very easy to configure a PC because of modularization, standardization, serialization of PLC.


Advantages of using PLC:

  1. Small physical size & shorter project time.
  2. Cost-effective for controlling complex systems.
  3. Reliability.
  4. Less and simple wiring.
  5. Faster response.
  6. Remote control capability.
  7. More flexibility.
  8. Ease of maintenance/troubleshooting.

Disadvantages of using PLC:

  1. Fixed circuit operation.
  2. PLCs manufacturers offer only closed loop architecture.
  3. PLCs are propitiatory, which means software and parts one manufacturer cannot be easily used in combination with part of another manufacturer.
  4. Number of optional modules must be added to maximize flexibility and performance.

 

Improvement from Industrial Revolution 3.0 to Industrial 4.0

            Industrial Revolution 4.0 is coined in 2011, representing the role that cyber-physical system (CPS), cloud computing, The Industrial Internet of Things (IIOT) will have on the manufacturing process. The difference between Industry 3.0 and Industry 4.0 that in Industry 3.0, the automated processes using logic processors and information technology. These processes often operate primarily without human interference, but there is still a human aspect behind them. Industry 4.0 comes in with the availability and use of vast quantities of data on the production floor.

            An example of the old way (Industry 3.0) is taking a CNC machine: while largely automated, it still needs input from a human controller. The process is automated based on human information, not by data. Under Industry 4.0, that same CNC machine would be able to follow set programming parameters and use data to streamline production processes.

            Thus, in our project, we need to implement system PLC replacement to new technology that is more productive, convenient to maintenance, and cost-effective to implement. For the proposed improvement technology that we selected is a dough machine mixer.        


 

Improvement System from PLC to Microcontroller Arduino

            From the previous system, the PLC that be used in the dough mixing machine. Then, our group has discussed among us to provide a new technology which is using Microcontroller Arduino into this dough mixing machine to replace the PLC system. After we go through the problem face, the PLC system is expensive for the company to buy and implement. It is estimated about 1000 U.S. dollars to buy the whole system. Next, this PLC has numerous PLC programming methods, including ladder logic, function block diagrams, structured text, instruction lists, and sequential flowcharts. Thus, it entirely gives confusion for the engineer to get along with the system. However, Microcontrollers excel in applications requiring limited computing functions. Despite this, they can perform a wide range of operations, including mathematical calculations, processing logic and data, controlling devices, and handling serial and wireless communications. In addition, microcontrollers are typically compact in size and inexpensive, with some models being obtainable for less than a hundred dollars.

Block Diagram of Existing Project

 

Flowchart of Existing Project.



Context Diagram of Existing Project.

 


Propose Solution of Improvement Project.



Example of Datasets Used to Develop the Dough Mixing Machine using AI model.

 

Resource of Dough Mixing Machine.



 


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