AUTOMATION OF DUAL EXTRUDER HYDRAULIC POWER PACK

AJAY P RAJ

PRINCE JOSE

HARI R

ATHULDEEP N

INTRODUCTION

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TYRE MANUFACTURING

• COMPOUND MIXING.

• EXTRUSION.

• CALENDERING.

• PLY CUTTING (BIAS CUTTING).

• TYRE BUILDING OR TYRE ASSEMBLING.

• TYRE CURING.

• POST CURE INFLATION.

• INSPECTION.

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THREAD EXTRUSION

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EXTRUDER

Types

• Ram Extruder.

• Gear Pump Extruder.

• Single Screw Extruder.

Dual Extruder

Power of motor 1= 3.7Kw.

Power of motor 2=2.2Kw.

Total Power=3.7+2.2= 5.9Kw.5

THREAD EXTRUSION BEFORE ADDING PLC

DUAL EXTRUDER

HYDRAULIC POWER PACK

THREAD

BASE CAP

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• No pressure sensing.

• Energy wastage.

• No control in the extrusion.

Time taken by two motors to work=18 hours.

Average load=85%.

Power consumption per day =5.9x.85x18=90KwH.

Rupees per unit=4.9

Energy Bill=4.9x90x30=Rs.13230

BLOCK DIAGRAM

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DUAL EXTRUDER

HYDRAULIC POWER PACKPLC

THREAD

BASE CAP

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PLC (Programmable logic controller)

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HISTORY OF PLC

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INSIDE A PLC

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INPUT MODULES

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DIGITAL vs ANALOG MODULES

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OUTPUT MODULES

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SIEMENS-S71200 PLC

• The S7-1200 series is a line of programmable logic controllers (PLCs).

• Can control a variety of automation applications.

• Compact design.

• low cost, and a powerful instruction set.

• A perfect solution for controlling a wide variety of applications.

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• 1200 models and the Windows-based programming tool give you the flexibility you need to solve your automation problems.

• The CPU combines a

Microprocessor

Integrated power supply

Input and Output circuits

Built-in PROFINET (port for communication over a network)

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Continued..

PROGRAMMING IN PLC

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DIFFERENT PROGRAMMING TECHNIQUES

• Function Block DiagramPictorial method of programming

Blocks for each function that show the inputs and outputs

• Instruction ListComplicated method

Assembly language

• Ladder DiagramLooks like a ladder with the inputs and outputs

Diagram looks like a wiring schematic

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•

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FLOWCHART

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PROCEDURE FOR PROGRAMMING

• Creating new project.

• Inserting &configuring CPU.

• Inserting & configuring Digital I/O module.

• Inserting & configuring Analog I/O module.

• Inserting tags .

• Ladder diagram Development.

• Program simulation.

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PLC INSTALLED SYSTEM

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SIEMENS S71200 CPU

Digital I/O Module

Analog module

MPCB

24 V POWER SUPPLY

440V-110 V TRANSFORMER

Relays

Contactor

MCB and ELCB

Pump 1 Pump 2 Contactor

RESULTS

AFTER PLC

• Time taken by two motors to work=4 hours.

• Average load=85%.

• Power consumption per day=5.9x.85x4=20KwH.

• Rupees per unit=4.9

• Energy Bill=4.9x20x30=Rs.2940

• Addition of PLC can save upto 70Kw (Rs.10290 / MONTH)

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ADVANTAGES

• Wastage of power can be reduced to a great extent.

• PLCs are easily programmed and have an easily understood programming language.

• Less and simple wiring.

• Increased Reliability.

• More Flexibility.

• Lower Cost .

• Faster Response.

• Easier to troubleshoot.

• Remote control capability.

• Communication Capability.

• Handles much more complicated systems.25

CONCLUSION

OLD SYSTEM

• No certain device to control the Dual Extruder.

• consume 90KWH per day.

AFTER ADDING PLC

• consume 20KWH per day .

• saving about 70KWH per day

• PLC automation can make a good impact in industrial sector.

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THANK YOU…

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