Category: uncategorised

Task Instructions: PLC Coursework Completion (Full Assignment)

You are required to complete a full individual coursework report for the module Programmable Logic Controller Design. The final submission must be professional, technically correct, and fully aligned with the given specifications.

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## General Requirements

– The report must be maximum 15 pages

– Follow IEEE conference format

– The work must be original and well-structured

– Include diagrams, flowcharts, and simulation results

– Include PLC program (Ladder Logic)

– Ensure clarity, correctness, and engineering accuracy

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# Part A: Literature Review (3 Pages)

## Step 1: Choose ONE topic from:

– Industry 4.0

– Wireless Sensors

– HMI

– SCADA

– OPC

– VFD

## Step 2: Write the report including:

### 1. Title & Abstract

– Clear title

– Abstract (max 250 words)

– Include purpose, method, key findings, and conclusion

### 2. Introduction

– Background of the topic

– Importance in industry

– Relation to PLC systems

– Define key terms

### 3. Methodology

– Explain how information was collected

– Describe technologies/components

– Include diagrams or tables

### 4. Discussion

– Analyze the topic

– Compare with other studies

– Explain advantages and limitations

### 5. Conclusion

– Summarize findings

– Provide recommendations

### 6. References

– Use IEEE referencing style

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# Part B1: Cement Industry (Sorting System Design)

## Objective:

Design and simulate a PLC-based system to sort cement boxes (Large, Medium, Small).

## System Requirements:

– Use sensors:

– X1 Large

– X2 Medium

– X3 Small

– Use pushers to direct boxes

– Use conveyor system

## Required Work:

### 1. System Design

– Clearly define:

– Inputs (Sensors, switches)

– Outputs (Motors, pushers)

– Draw system diagram

### 2. Control Algorithm

– Provide step-by-step logic

– Draw Flowchart

### 3. PLC Program (IMPORTANT)

– Write Ladder Logic program including:

– Start/Stop logic

– Conveyor control

– Sensor-based sorting

– Pusher activation

– Safety conditions

### 4. Simulation

– Use Mitsubishi FX Simulator

– Show:

– System running

– Sorting process

– Include screenshots or explanation

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# Part B2: Plastic Industry (Advanced System)

## Objective:

Design a more advanced sorting system using:

– Conveyor

– Robot

– Sorting wing

## Required Work:

### 1. System Design

– Inputs and outputs clearly defined

– Include robot and sensors

### 2. Control Logic

– Explain how:

– Large, medium, small parts are handled

– Include flowchart

### 3. PLC Programming

– Ladder Logic must include:

– Robot control (Y7)

– Sorting wing (Y3)

– Conveyor logic

– Automatic operation (SW2)

### 4. Simulation

– Show working system

– Include explanation and results

### 5. Indicators

– Red light Robot working

– Green Conveyor running

– Yellow Stopped

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# Final Deliverables

– Full report (15 pages)

– PLC Ladder Logic code

– Simulation results (screenshots or explanation)

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# Important Notes

– Ensure all parts are complete and correct

– Use clear engineering explanation

– Avoid plagiarism

– Follow academic formatting strictly

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## Expected Outcome

The final work should demonstrate:

– Strong understanding of PLC systems

– Ability to design real industrial automation

– Correct programming and simulation

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Complete the task with high accuracy and professional quality.

You are required to complete the coursework for the module Sensors, Transducers and Actuators as a group of 4 students. The final submission must be a professional report (maximum 15 pages) along with a working simulation and recorded demonstration video.

The work must be completed accurately, professionally, and in full compliance with the given coursework specifications.

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### Part 1: Individual Research (Literature Review)

Each of the 4 group members must independently prepare a 3-page research report using the IEEE format.

#### Requirements:

– Each student must select a different type of industrial sensor (e.g., Temperature, Pressure, Proximity, Optical, Flow, etc.).

– The report must include:

1. Title

2. Abstract (max 250 words)

3. Introduction

4. Methodology

5. Discussion

6. Conclusion

7. References (IEEE style)

#### Notes:

– Ensure clarity, depth of analysis, and use of recent academic sources.

– Each report must be well-structured and technical, not descriptive only.

– Total pages for this part = 12 pages (4 students 3 pages)

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### Part 2: System Design and Simulation (Group Work)

As a team, design and simulate an automated cement bag sorting system based on size (Large, Medium, Small).

#### System Description:

– Cement bags move on a conveyor belt.

– Sensors detect the size of each bag.

– A lifting mechanism transfers the bag to one of three levels:

– Upper Large

– Middle Medium

– Lower Small

– Each level has its own conveyor to deliver bags to storage.

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### Tasks to Complete:

#### 1. Technical Requirements:

– Identify and justify:

– Types and number of sensors used

– Number of conveyors

– Actuators (motors, lift, etc.)

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#### 2. System Design:

– Provide:

– Block diagram or system layout

– Flowchart or control algorithm

– Step-by-step operation of the system

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#### 3. Programming & Simulation:

– Use Mitsubishi FX Simulator

– Develop a PLC control program that:

– Controls conveyors based on sensors

– Sorts bags correctly

– Controls lift movement (up/down/rotate)

– Applies timing conditions (e.g., 3-second delay after detection)

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#### 4. Demonstration Video:

– Record a video that shows:

– The simulation running

– System behavior (sorting process)

– Explanation of how the system works

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### Important Control Conditions:

– Conveyors operate when switch is ON

– Sensors trigger movement of conveyors

– Conveyors stop after a delay

– Lift moves based on size detection:

– Large Upper

– Medium Middle

– Small Lower

– Lift must return to initial position after each operation

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### Final Submission:

– Combine everything into ONE report (max 15 pages):

– 12 pages Individual research

– 3 pages Group system design

– Attach:

– PLC program

– Simulation results

– Video recording

– SafeAssign report

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### Important Notes:

– The work must be accurate, complete, and simulation must function correctly

– Use proper engineering terminology and formatting

– Avoid plagiarism and ensure originality

– The system must clearly demonstrate automation and correct sorting

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### Goal:

Deliver a fully functional, well-documented industrial automation system supported by simulation, analysis, and proper engineering design