View
217
Download
0
Category
Preview:
Citation preview
7/30/2019 Automated Personal Shopping System Using Plc
1/62
7/30/2019 Automated Personal Shopping System Using Plc
2/62
2
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.
7/30/2019 Automated Personal Shopping System Using Plc
3/62
3
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
7/30/2019 Automated Personal Shopping System Using Plc
4/62
4
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.
7/30/2019 Automated Personal Shopping System Using Plc
5/62
5
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.
7/30/2019 Automated Personal Shopping System Using Plc
6/62
6
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.
7/30/2019 Automated Personal Shopping System Using Plc
7/62
7/30/2019 Automated Personal Shopping System Using Plc
8/62
8
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.
7/30/2019 Automated Personal Shopping System Using Plc
9/62
9
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
7/30/2019 Automated Personal Shopping System Using Plc
10/62
10
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=17/30/2019 Automated Personal Shopping System Using Plc
11/62
7/30/2019 Automated Personal Shopping System Using Plc
12/62
12
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_logic7/30/2019 Automated Personal Shopping System Using Plc
13/62
13
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_logic7/30/2019 Automated Personal Shopping System Using Plc
14/62
14
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
7/30/2019 Automated Personal Shopping System Using Plc
15/62
15
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
7/30/2019 Automated Personal Shopping System Using Plc
16/62
16
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.
7/30/2019 Automated Personal Shopping System Using Plc
17/62
17
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.
7/30/2019 Automated Personal Shopping System Using Plc
18/62
18
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
7/30/2019 Automated Personal Shopping System Using Plc
19/62
19
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
7/30/2019 Automated Personal Shopping System Using Plc
20/62
20
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
7/30/2019 Automated Personal Shopping System Using Plc
21/62
21
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)
7/30/2019 Automated Personal Shopping System Using Plc
22/62
22
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_handling7/30/2019 Automated Personal Shopping System Using Plc
23/62
23
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
7/30/2019 Automated Personal Shopping System Using Plc
24/62
24
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
7/30/2019 Automated Personal Shopping System Using Plc
25/62
25
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.
7/30/2019 Automated Personal Shopping System Using Plc
26/62
26
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
7/30/2019 Automated Personal Shopping System Using Plc
27/62
27
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
7/30/2019 Automated Personal Shopping System Using Plc
28/62
28
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
7/30/2019 Automated Personal Shopping System Using Plc
29/62
29
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.
7/30/2019 Automated Personal Shopping System Using Plc
30/62
30
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
7/30/2019 Automated Personal Shopping System Using Plc
31/62
31
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.
7/30/2019 Automated Personal Shopping System Using Plc
32/62
32
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
7/30/2019 Automated Personal Shopping System Using Plc
33/62
7/30/2019 Automated Personal Shopping System Using Plc
34/62
34
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.
7/30/2019 Automated Personal Shopping System Using Plc
35/62
7/30/2019 Automated Personal Shopping System Using Plc
36/62
36
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.
7/30/2019 Automated Personal Shopping System Using Plc
37/62
37
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.
7/30/2019 Automated Personal Shopping System Using Plc
38/62
38
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
7/30/2019 Automated Personal Shopping System Using Plc
39/62
39
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.
7/30/2019 Automated Personal Shopping System Using Plc
40/62
40
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
7/30/2019 Automated Personal Shopping System Using Plc
41/62
41
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.
7/30/2019 Automated Personal Shopping System Using Plc
42/62
7/30/2019 Automated Personal Shopping System Using Plc
43/62
43
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.
7/30/2019 Automated Personal Shopping System Using Plc
44/62
44
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.
7/30/2019 Automated Personal Shopping System Using Plc
45/62
45
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.
7/30/2019 Automated Personal Shopping System Using Plc
46/62
46
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.
7/30/2019 Automated Personal Shopping System Using Plc
47/62
47
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.
7/30/2019 Automated Personal Shopping System Using Plc
48/62
48
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,
7/30/2019 Automated Personal Shopping System Using Plc
49/62
49
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
7/30/2019 Automated Personal Shopping System Using Plc
50/62
50
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
7/30/2019 Automated Personal Shopping System Using Plc
51/62
51
EXAMPLE :
Fig 4.13 Example program
7/30/2019 Automated Personal Shopping System Using Plc
52/62
52
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.
7/30/2019 Automated Personal Shopping System Using Plc
53/62
7/30/2019 Automated Personal Shopping System Using Plc
54/62
54
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.
7/30/2019 Automated Personal Shopping System Using Plc
55/62
55
Table 5.2 Digital outputs from PLC
7/30/2019 Automated Personal Shopping System Using Plc
56/62
56
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.
7/30/2019 Automated Personal Shopping System Using Plc
57/62
57
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.
7/30/2019 Automated Personal Shopping System Using Plc
58/62
58
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
7/30/2019 Automated Personal Shopping System Using Plc
59/62
59
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.
7/30/2019 Automated Personal Shopping System Using Plc
60/62
7/30/2019 Automated Personal Shopping System Using Plc
61/62
61
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
7/30/2019 Automated Personal Shopping System Using Plc
62/62
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.pdfRecommended