Design and construction of fountain system

Final product: - Completely simulating reality fountain system - System report book Trang 4 THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness --- Ho Chi Minh City, De

MINISTRY OF EDUCATION AND TRAINING

HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION

FACULTY FOR HIGH QUALITY TRAINING

GRADUATION PROJECT ELECTRONICS AND ELECTRONIC ENGINEERING TECHNOLOGY

DESIGN AND CONSTRUCTION OF FOUNTAIN SYSTEM

ADVISOR : M.E NGUYEN TAN DOI STUDENTS: VO ANH KHOA

LE HOANG HOP

S K L 0 1 0 5 7 6

HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION

FACULTY FOR HIGH QUALITY TRAINING

Ho Chi Minh City, December 2022

DESIGN AND CONSTRUCTION OF FOUNTAIN SYSTEM

GRADUATION PROJECT

Advisor: M.E NGUYEN TAN DOI

Student name: VO ANH KHOA ID: 18142032

Student name: LE HOANG HOP ID: 18142024

Major: ELECTRICAL AND ELECTRONIC ENGINEERING TECHNOLOGY

THE SOCIALIST REPUBLIC OF VIETNAM

Independence – Freedom– Happiness

-

Ho Chi Minh City, December 28, 2022

GRADUATION PROJECT ASSIGNMENT Student name: VO ANH KHOA Student ID: 18142032 Class: 18142CLA3

Phone number: 0938513252

Major: ELECTRICAL AND ELECTRONIC ENGINEERING TECHNOLOGY

Student name: LE HOANG HOP Student ID: 18142024 Class: 18142CLA2

Phone number: 0965684440

Major: ELECTRICAL AND ELECTRONIC ENGINEERING TECHNOLOGY

Advisor: M.E NGUYEN TAN DOI Phone number: 0983222159

Date of assignment: 26/09/2022 Date of submission: 28/12/2022

1 Project title: DESIGN AND CONSTRUCTION OF FOUNTAIN SYSTEM

2 Initial materials provided by the advisor

- Survey the reality fountain

- Learn the principle and setting variable frequency drive

- Learn Modbus communication

3 Content of the project:

- Design fountain model

- Construction system

- Programing PLC for controlling system

- Communication between PLC and VFD

- Design HMI interface

4 Final product:

- Completely simulating reality fountain system

- System report book

THE SOCIALIST REPUBLIC OF VIETNAM

Independence – Freedom– Happiness

-

Ho Chi Minh City, December 28, 2022

ADVISOR’S EVALUATION SHEET Student name: VO ANH KHOA Student ID: 18142032

Student name: LE HOANG HOP Student ID: 18142032

Major: ELECTRICAL AND ELECTRONIC ENGINEERING TECHNOLOGY

Project title: DESIGN AND CONSTRUCTION OF FOUNTAIN SYSTEM

Advisor: M.E NGUYEN TAN DOI

THE SOCIALIST REPUBLIC OF VIETNAM

Independence – Freedom– Happiness

-

Ho Chi Minh City, December 28, 2022 PRE-DEFENSE EVALUATION SHEET Student name: VO ANH KHOA Student ID: 18142032 Student name: LE HOANG HOP Student ID: 18142032 Major: ELECTRICAL AND ELECTRONIC ENGINEERING TECHNOLOGY Project title: DESIGN AND CONSTRUCTION OF FOUNTAIN SYSTEM Name of Reviewer:

EVALUATION 1 Content and workload of the project

2 Strengths:

3 Weaknesses:

4 Approval for oral defense? (Approved or denied)

6 Reviewer’ questions for project valuation

6 Mark: ……… (in words: )

Ho Chi Minh City, December 28, 2022

REVIEWER

ACKNOWLEDGEMENT

When completing this graduation project, the group is also nearing the end of their study time

at Ho Chi Minh City University of Technology and Education The time spent studying and researching at the University has helped the group understand and love this place more The school and teachers not only impart to the group professional knowledge but also educate us about ideals and ethics in life These are indispensable luggage for the life and career of the group later The group would like to express its deep gratitude to all the teachers who have enthusiastically guided and led the group to this day so that they can firmly walk on the path of study and work in the future

The graduation project marked the completion of the group's years of hard work And this project also marks the maturity on the learning path of the group Through this, the team would like to thank family and friends who have always encouraged and created all conditions for the group to complete the course

Finally, the group would like to express its deepest gratitude to Mr Nguyen Tan Doi with his enthusiasm for helping, creating favorable conditions and his correct and timely orientation, which helped the group a lot in the process of implementing the project

From the bottom of our heart Thank you so much!

ABSTRACT

With the more condominium expansion, the more entertainments requirement for residents Not only cuisine serving, shopping but also the entertainment art must upgrade Besides that, large square and walking street are planning, so the demand of amusing plays an important role in residents’ life That is a big chance for automation companies, especially related art ones Therefore, the water music fountain was designed for needed which have noticed above Not just bringing unique, interested in spectators It is also considered that this is a big change in entertainment industrial But it too economic consuming to design or install a water music fountain in the place have small space

Because of knowing this issue, our group choose "Applying variable frequency drive for fountain system" topic to support and resolve problem for person is living in the house place have not large area and medium incoming However, if our group want this problem is resolved

in best optimally, we must solve each question such as what is water music fountain? how optimizing construction space? which control equipment suitable for system?

To answer those question, our group had designed small simulation model of the fountain operation Firstly, our group have to determine the space area to construct a system and then design system in emulator software Secondly, select the wanted effect and purchase accordant electric equipment Finally, writing control program for system

During experiment process, our group must test the accuracy working of variable frequency drive, data transfer speed of Modbus protocol Moreover, the electric board construction must

as careful as possible because of the system have diversity about power supply, dynamic circuit, and control circuit

ADDENDUM

ACKNOWLEDGEMENT

ABSTRACT

CHAPTER I INTRODUCTION 1

1.1 The reason for choosing topic 1

1.2 Objectives and research methods 1

1.3 Limits of the topic 2

CHAPTER II THEORETICAL BASIS 3

2.1 Overview of the fountain system 3

2.2 Variable frequency drive 3

2.3 Programable logic controller 9

2.4 Modbus communication 12

2.5 Three-phase pump 15

2.6 Solenoid valve 16

2.7 Fountain nozzle 21

2.8 TIA Portal software 24

2.9 Modbus Poll 27

CHAPTER III SYSTEM CALCULATE AND DESIGN 31

3.1 Mechanical design 31

3.2 Electrical design 34

3.3 Flowchart design 40

CHAPTER IV SYSTEM CONSTRUCTION 42

4.1 Mechanical construction 42

4.2 Electrical construction 43

4.3 VFD setting and communication 45

4.4 PLC programming 52

4.5 Human Machine Interface 56

CHAPTER V EXPERIMENTAL RESULT 59

5.1 Mechanical result 59

5.2 Electrical result 59

5.3 Control and monitor result 60

CHAPTER VI CONCLUSION AND RECOMMENDATIONS 63

6.1 Conclusion 63

6.2 Development 63

REFERENCES 64

Picture’s addendum

Figure 2.2.1 Variable Frequency Drive’s structure [9]

Figure 2.2.2 Voltage Source Inverter type [9]

Figure 2.2.3 Current Source Inverter type [9]

Figure 2.2.4 Pulse Width Modulation type [9]

Figure 2.3.1 Programmable Logic Controller’s structure [10]

Figure 2.4.1 Half Duplex system [11]

Figure 2.4.2 Full Duplex system [11]

Figure 2.6.1 Solenoid valve’s structure [12]

Figure 2.6.2 Solenoid valve reality [12]

Figure 2.6.3 De-energized mode [12]

Figure 2.6.4 Energized mode [12]

Figure 2.6.5 De-energized of direct acting type [12]

Figure 2.6.6 Energized of direct acting type [12]

Figure 2.6.7 De-energized of indirect acting type [12]

Figure 2.6.8 Energized of indirect acting type [12]

Figure 2.6.9 De-energized of semidirect acting type [12]

Figure 2.6.10 Energized of semidirect acting type [12]

Figure 2.6.11 AC voltage solenoid [12]

Figure 2.6.12 DC voltage solenoid [12]

Figure 2.6.13 Water flow direction [12]

Figure 2.6.14 Installation regulation [12]

Figure 2.7.1 Single fountain nozzle

Figure 2.7.2 Effect single fountain nozzle

Figure 2.7.3 Multi-fountain nozzle

Figure 2.7.4 Effect multi-fountain nozzle

Figure 2.7.5 Geyser jet nozzle

Figure 2.7.6 Effect geyser jet nozzle

Figure 2.7.7 Umbrella nozzle

Figure 2.7.8 Effect umbrella nozzle

Figure 2.8.1 Software interface

Figure 2.8.3 WinCC interface

Figure 2.8.4 Simatic start driver interface Figure 2.8.5 Sirius and Simocode interface Figure 2.8.6 Scout TIA interface

Figure 2.9.1 Setup interface

Figure 2.9.2 Control interface

Figure 2.9.3 Connection interface

Figure 2.9.4 Connection interface

Figure 2.9.5 Modbus function interface Figure 2.9.6 Setup function interface

Figure 2.9.7 Log data to a text file

Figure 2.9.8 Log data direct into excel

Figure 2.9.9 Display format interface

Figure 2.9.10 Setup format interface

Figure 3.1.1 Radius of two curves

Figure 3.1.2 Distance between two nozzles Figure 3.1.3 Nozzle sample

Figure 3.1.4 Nozzle parameters

Figure 3.1.5 Nozzle position

Figure 3.1.6 Frame parameters

Figure 3.1.8 Mica material

Figure 3.1.10 Water pipelines drawing

Figure 3.1.11 Sewer pipelines drawing

Figure 3.2.1 Control system block diagram

Figure 3.2.4 AC/DC adapter

Figure 3.2.6 Pin diagram [1]

Figure 3.2.7 Pin configuration of S7 1200 [1]

Figure 3.2.8 CM 1241 RS422/RS485

Figure 3.2.9 Port connection

Figure 3.2.10 Pin configuration of module [1]

Figure 3.2.11 Profibus connector

Figure 3.2.12 Profibus connector parameters [4]

Figure 3.2.13 Fuji Frenic Mini

Figure 3.2.14 Fuji parameters

Figure 3.2.15 Fuji interface [2]

Figure 3.2.16 Wilo pump

Figure 3.2.17 Grundfos pump

Figure 3.2.18 Solenoid valve

Figure 3.2.19 Solenoid valve

Figure 3.2.20 Omron relay

Figure 3.2.21 Relay base

Figure 3.2.22 Wiring diagram system

Figure 3.4 Control flowchart

Figure 4.1.1 Frame construction

Figure 4.1.2 Water tank construction

Figure 4.1.3 Nozzles construction

Figure 4.1.4 Pipelines and solenoid construction

Figure 4.1.5 Pump installation

Figure 4.2.1 Installing power source

Figure 4.2.2 Expanding terminal

Figure 4.2.3 Installing button

Figure 4.2.4 Installing solenoid valve

Figure 4.3.1 Fuji controlling panel

Figure 4.3.2 Setting capacity for Wilo pump

Figure 4.3.3 Setting rated current for Wilo pump

Figure 4.3.4 Setting capacity for Grundfos pump

Figure 4.3.5 Setting rated current for Grundfos pump

Figure 4.3.6 Setting maximum frequency for Wilo pump

Figure 4.3.8 Setting base frequency for Wilo pump

Figure 4.3.9 Setting base frequency for Grundfos pump

Figure 4.3.10 Setting rated voltage for Wilo pump

Figure 4.3.11 Setting rated voltage for Grundfos pump

Figure 4.3.12 Setting maximum output voltage for Wilo pump

Figure 4.3.13 Setting maximum output voltage for Grundfos pump

Figure 4.3.14 Setting communication link function for Wilo pump

Figure 4.3.15 Setting communication link function for Grundfos pump Figure 4.3.16 Setting protection/maintenance function for Wilo pump Figure 4.3.17 Setting protection/maintenance function for Grundfos pump Figure 4.3.18 Setting station address for Wilo pump

Figure 4.3.19 Setting station address for Grundfos pump

Figure 4.3.20 Setting communication error processing for Wilo pump Figure 4.3.21 Setting communication error processing for Grundfos pump Figure 4.3.22 Setting timer error detect for Wilo pump

Figure 4.3.23 Setting timer error detect for Grundfos pump

Figure 4.3.24 Setting baud rate for Wilo pump

Figure 4.3.25 Setting baud rate for Grundfos pump

Figure 4.3.26 Setting data length for Wilo pump

Figure 4.3.27 Setting data length for Grundfos pump

Figure 4.3.28 Setting parity check for Wilo pump

Figure 4.3.29 Setting parity check for Grundfos pump

Figure 4.3.30 Setting stop bit for Wilo pump

Figure 4.3.31 Setting stop bit for Grundfos pump

Figure 4.3.32 Setting protocol for Wilo pump

Figure 4.3.33 Setting protocol for Grundfos pump

Figure 4.3.34 Setting loader link function for Wilo pump

Figure 4.3.35 Setting loader link function for Grundfos pump

Figure 4.4.1 Modules declare

Figure 4.4.2 Setting parameters for CM 1241

Figure 4.4.4 Add data into MB_Comm_Load block

Figure 4.4.5 MB_Master block

Figure 4.4.6 Function code group/code conversion table [3]

Figure 4.4.7 Command data table [3]

Figure 4.4.8 Add data into MB_Master block

Figure 4.4.9 Add data into MB_Master block

Figure 4.4.10 PLC program

Figure 4.5.1 HMI start screen interface

Figure 4.5.2 HMI start screen parameter

Figure 4.5.3 Create function button

Figure 4.5.4 Create function button

Figure 4.5.5 Arrange equipment position

Figure 4.5.6 Setting display status

Figure 4.5.7 HMI start screen interface

Figure 4.5.8 HMI controlling screen interface

Figure 5.1.1 Completed nozzles position

Figure 5.1.2 Completed nozzles position

Figure 5.1.3 Completed pipelines and sewage

Figure 5.1.4 Completed pipelines and sewage

Figure 5.2.1 Pumps and solenoids installation

Figure 5.2.2 Completed electrical board

Figure 5.3.1 LEDs run indicator

Figure 5.3.2 Relays operation

Figure 5.3.3 Fuji operation

Figure 5.3.4 PLC operation

Figure 5.3.5 Water column effect

Figure 5.3.6 Water column effect

Figure 5.3.7 HMI operation

Figure 5.3.8 HMI operation

Figure 5.3.9 Water column effect

Figure 5.3.10 Water column effect

CHAPTER I INTRODUCTION 1.1 The reason for choosing topic

With the higher demand for art and entertainment of the people, music or picture exhibitions are not enough to satisfy viewers Perceiving art through a sense is not optimizing the value of modern art Therefore, the water entertainment system gradually appeared to satisfy everyone's entertainment needs, especially in tourist areas Not only increasing the number of visitors but also boosting the economy for the tourist city but for the whole country in general

However, the design and construction of a fountain system is very expensive and occupies a lot of construction space The project of our group is to focus on factors such

as saving costs, taking advantage of small empty areas in private houses or apartments, and still being able to construct a system which satisfy viewers not only auditory sense but also visual sense

1.2 Objectives and research methods

The main goal of this project is to design and construct a model that can simulate the operation of a fountain system In addition, it is possible to monitor and control the system according to the wishes of the user or system operator through the HMI interface

Through studying and based on fountain systems available in the market, our team has improved the signal processing unit with a PLC device instead of using multiple control boards but still ensures the quality of the signal synchronous operation of discrete devices in the system Besides, instead of using inverter and water pump with voltage level of 380Vac, the use of equipment with voltage level of 220Vac has reduced equipment costs and is easy to apply for households After selecting the right equipment for the project, the next step will be to program the operations for each device and the effects of the water column to match the melody of the song Check the effects many times to observe the coordination of each device and create as much harmony for the viewer as possible

1.3 Limits of the topic

- The system can only run according to pre-programmed programs, cannot control changes by itself according to external signals such as music,

- Using WinCC software for simulation as there is no actual HMI monitoring device

- The water columns only spray in the vertical direction, there are no effects such

as the geyser jet nozzle effect, an umbrella nozzle effect

- Can only monitor and control the system at close range

CHAPTER II THEORETICAL BASIS 2.1 Overview of the fountain system

This is an architectural design where water is poured into a tank or sprayed into the air

It creates a very impressive effect and is considered a masterpiece of decorative arts Fountains work on the principle of pressure The water pump will absorb from the water tank and then bring it to the nozzle Under the pressure of the pump, it will create a column of water perpendicular to the water surface or an arc-shaped water column This process has been pre-programmed according to a certain standard With different nozzle models, it will create different water columns and bring different aesthetic values

2.2 Variable frequency drive

2.2.1 Definition

VFD is a power electronics-based device which converts a basic fixed frequency, fixed voltage sine wave power (line power) to a variable frequency, variable output voltage used to control speed of induction motor(s) It regulates the speed of a three-phase induction motor by controlling the frequency and voltage of the power supplied to the motor

Figure 2.2.1

- Rectifier: A full-wave power diode based solid-state rectifier converts phase 50 Hz power from a standard 220, 440 or higher utility supply to either fixed or adjustable DC voltage The system may include transformers for high voltage system

three Filter: provides a smooth, rectified DC voltage as IGBT, GTO or SCR switch the

DC power from rectifier on and off to produce a current or voltage waveform at the required new frequency Presently most of the voltage source inverters use pulse width modulation (PWM) because the current and voltage waveform at output in this scheme is approximately a sine wave Power Electronic switches such as IGBT; GTO etc switch DC voltage at high speed, producing a series of short-width pulses of constant amplitude Output voltage is varied by varying the gain of the inverter Output frequency is adjusted by changing the number of pulses per half cycle or by varying the period for each time cycle

- Control system: Its function is to control output voltage; voltage vector of inverter being fed to motor and maintain a constant ratio of voltage to frequency (V/Hz) It consists of an electronic circuit which receives feedback information from the driven motor and adjusts the output voltage or frequency to the desired values Control system may be based on SPWM (Sine Wave PWM), SVPWM (Space Vector modulated PWM) or some soft computing-based algorithm

In addition, the VFDs is integrated with a number of other parts such as: AC resistor,

DC resistor, brake resistor (discharge resistor), keyboard, display screen, communication module,

The drawback of VSI is that they have poor power factors as well as they cause motor cogging at a low frequency below 6 Hz Apart from that, they are also non-regenerative i.e., they cannot store the energy flowing back from the motor

Figure 2.2.2

- CSI type VFDs

CSI or Current Source Inverter type VFD provides a smooth current waveform as opposed to the smooth voltage waveform of the VSI type It utilizes large inductors and expensive inductors to store and deliver steady DC current

It is made of SCR-based rectifiers for AC to DC conversion with a series of inductors for filtering and storing the DC current The inverter converts the DC current into alternating current The CSI-type VFDs have regenerative power capabilities i.e they store the energy that flows back from the load such as a motor but they also cause motor cogging at a low frequency below 6Hz They are mostly used in signal processing

Figure 2.2.3

- PWM type VFDs

PWM or Pulse Width Modulation is a technique where the duty cycle of a signal is varied to vary the average power delivered PWM-based VFD uses fixed DC voltage pulses of different duty cycles to simulate a sinusoidal waveform It is an improved version of VSI; therefore, it provides stable voltage with an improved power factor

It has a simple diode bridge rectifier that converts AC into DC The Control Unit is programmed to control the duty cycle of the inverted output by adjusting the switching speed of the inverter It also requires an extra regulator at its output to regulate the voltage pulses and provide a smooth voltage and current waveform

It is the most common method used in VFDs due to its numerous advantages over the VSI and CSI VFD For instance, it does not cause cogging in motor with improved efficiency It has a better power factor But they are quite complex to design and implement They also require an additional circuit for voltage and current regulation

Figure 2.2.4

- Lifts and escalators use the smooth start and stop feature of VFD

- They are used for water pumps and also for crushers in mining

- Hoist and crane use VFD for precise control of speed and positioning

2.2.5 Advantages and disadvantages

Advantages:

VFD not only provides variable speed control but also offers energy saving with improved efficiency and simple control Here are some of the advantages or benefits of VFD:

- Improved Efficiency: The conventional speed control using the variable voltage method wastes a lot of energy as compared to the variable frequency method Therefore, VFD is used in industries to increase motor efficiency and conserve

a great amount of energy

- Precise Control: A VFD allows tighter control of the speed using a sensor to run the motor at an efficient speed that does not cause hindrance and increases the production speed in the industries

- Limits Inrush Current: Inrush current is the huge starting current drawn by an induction motor during its startup it is 5 to 8 times greater than its rated current

It can damage the windings of the motor The VFD can safely limit the starting current and it is used in one of the methods for induction motor starting

- Extend Mechanical Life: It can safely start and stop a motor with a gradual change in speed without any mechanical jerks It extends the mechanical life of the motor

- Reduced Maintenance: Smooth operation of motors reduces the mechanical stress and eliminates the jerks that eventually reduce the maintenance required for such motor Thus, reducing the long-term cost

- Power Factor: A poor power factor causes reactive power loss that is the energy wasted in the form of heat Induction motor usually has a low power factor A VFD improves the power factor to utilize the power more efficiently

- Protection: A VFD can also provide protection against overload, over-voltage and phase loss It immediately stops the supply current in case of such faults to protect the load connected from damage

- Easy installation: They are easier to install and operate since they are programmed during manufacturing with easy to operate and friendly user interface

- Special Motor Design: The PWM-based AC output of VFD is not pure sinusoid

It can create stress in the windings of a normal AC motor that can heat up and degrade the winding insulation Therefore, a special motor with improved insulation design rated for PWM inverter is required for running with VFD

- Harmonics: The VFD can create harmonic in the supply The non-linear current draw of the rectifier circuit creates distortion in the supply that affects the electrical equipment connected in parallel Therefore, it requires extra harmonic filters

- Complex Operation: As compared to direct on-line DOL or across the line starter, the operation, and settings of VFD is complex Modern VFDs have a

more user-friendly interface, but still, it cannot compete with the direct on-line starter simple push-button operation

- Extreme Environment: As compared to the DOL starter, the electronic circuitry

in VFD is sensitive and its operation is affected by extreme cold or heat It requires additional measures to cope with such an extreme environment

2.3 Programable logic controller

2.3.1 Definition

A programmable logic controller (PLC) is a type of tiny computer that can receive data through its inputs and send operating instructions through its outputs Fundamentally, a PLC’s job is to control a system’s functions using the internal logic programmed into

it A PLC takes in inputs, whether from automated data capture points or from human input points such as switches or buttons Based on its programming, the PLC then decides whether or not to change the output A PLC’s outputs can control a huge variety

of equipment, including motors, solenoid valves, lights, switchgear, safety shut offs and

many others

2.3.2 Structure

The structure of a PLC is almost similar to a computer’s architecture Programmable Logic Controllers continuously monitors the input values from various input sensing devices (e.g., accelerometer, weight scale, hardwired signals, etc.) and produces corresponding output depending on the nature of production and industry A typical block diagram of PLC consists of five parts namely:

- Rack or chassis:

In all PLC systems, the PLC rack or chassis forms the most important module and acts

as a backbone to the system PLCs are available in different shapes and sizes When more complex control systems are involved, it requires larger PLC racks

Small-sized PLC is equipped with a fixed I/O pin configuration So, they have gone for modular type rack PLC, which accepts different types of I/O modules with sliding and fit in concept All I/O modules will be residing inside this rack/chassis

- Power Supply Module:

This module is used to provide the required power to the whole PLC system It converts the available AC power to DC power which is required by the CPU and I/O module PLC generally works on a 24V DC supply Few PLC uses an isolated power supply

- Central Processing Unit (CPU)

CPU module has a central processor, ROM & RAM memory ROM memory includes

an operating system, drivers, and application programs RAM memory is used to store programs and data CPU is the brain of PLC with an octal or hexagonal microprocessor Being a microprocessor-based CPU, it replaces timers, relays, and counters Two types

of processors as a single bit or word processor can be incorporated with a PLC One bit processor is used to perform logic functions Whereas word processors are used for processing text, numerical data, controlling, and recording data

CPU reads the input data from sensors, processes it, and finally sends the command to controlling devices DC power source, as mentioned in the previous discussion is required voltage signals CPU also contains other electrical parts to connect cables used

by other units

- Input & Output Module

Input devices can be either start and stop pushbuttons, switches, etc and output devices can be an electric heater, valves, relays, etc I/O module helps to interface input and output devices with a microprocessor

- Communication Interface Module

To transfer information between CPU and communication networks, intelligent I/O modules are used These communication modules help to connect with other PLCs and computers which are placed at a remote location

Figure 2.3.1

2.3.3 Types of PLC

PLC are divided into three types based on output namely Relay output, Transistor output, and Triac Output PLC The relay output type is best suited for both AC and DC output devices Transistor output type PLC uses switching operations and used inside microprocessors According to the physical size, a PLC is divided into Mini, Micro, and Nano PLC

2.3.4 Applications

- It is used in civil applications such as washing machine, elevators working and traffic signals control

- It is used in aerospace for Water tank quenching system

- It is used to reducing the human control allocation of human sequence given to the technical equipment’s that is called Automation

- It is used in batch process in chemical, cement, food, and paper industries are sequential in nature, requiring time or event-based decisions

- It is used in the burner management system to control the process of purging, pilot light off, flame safety checks, main burner light off and valve switching for changeover of fuels

- It is used in printing industry for multistage screen washing system and Offset web press print register control system

- It is used in travel industry for escalator operation, monitored safety control system

2.3.5 Advantages and disadvantages

Advantages:

- PLCs are fairly intuitive to program Their programming languages are simple

in comparison to other industrial control systems, which makes PLCs great for businesses that want to minimize complexity and costs

- PLCs are a mature technology with years of testing and analysis backing them

up It’s easy to find robust research about many different PLC types and comprehensive tutorials for programming and integrating them

- PLCs are available at a wide range of price points, including many extremely affordable basic models that small businesses and startups often use

- PLCs are extremely versatile, and most PLC models are suitable for controlling

a wide variety of processes and systems

- PLCs are completely solid-state devices, which means they have no moving parts That makes them exceptionally reliable and more able to survive the challenging conditions present in many industrial facilities

- PLCs have relatively few components, which makes them easier to troubleshoot and helps reduce maintenance downtime

- PLCs are efficient and don’t consume very much electrical power This helps conserve energy and may simplify wiring considerations

Disadvantages:

- PLCs have less capacity to handle extremely complex data or large numbers of processes that involve analog rather than discrete inputs As manufacturing facilities become more integrated and involved, increasing numbers of them may shift toward a distributed control system or another alternative industrial control method

- PLCs from different manufacturers often use proprietary programming software This makes PLC programming interfaces less interoperable than they might be, especially considering that their programming languages share common standards

- PLCs, like many other types of electronic equipment, are vulnerable to electromagnetic interference (EMI) They can also experience other kinds of common electronics malfunctions such as corrupted memory and communication failures

2.4 Modbus communication

2.4.1 Definition of communication protocol

In telecommunications, a communication protocol is a system of rules that allow two

or more entities of a communication system to communicate between them to transmit information via any kind of variation of a physical quantity These are the rules or

standard that defines the syntax, semantics and synchronization of communication and possible error recovery methods Protocols may be implemented by hardware, software,

or a combination of both

Communicating systems use well-defined formats (protocol) for exchanging messages Each message has an exact meaning intended to elicit a response from a range of possible responses pre-determined for that particular situation The specified behavior

is typically independent of how it is to be implemented Communication protocols have

to be agreed upon by the parties involved To reach agreement, a protocol may be developed into a technical standard A programming language describes the same for computations, so there is a close analogy between protocols and programming languages: protocols are to communications as programming languages are to computations

2.4.2 Definition of Modbus protocol

Modbus RTU is an open serial protocol derived from the master/slave architecture (now client/server) originally developed by Modicon (now Schneider Electric) It is a widely accepted serial level protocol due to its ease of use and reliability Modbus RTU is widely used within Building Management Systems (BMS) and Industrial Automation Systems (IAS)

Modbus RTU messages are a simple 16-bit structure with a Cyclic-Redundant Checksum The simplicity of these messages ensures reliability Due to this simplicity, the basic 16-bit Modbus RTU register structure can be used to pack in floating point, tables, ASCII text, queues, and other unrelated data

This protocol primarily uses an RS-232 or RS-485 serial interfaces for communications and is supported by every commercial SCADA, HMI, OPC server and data acquisition software program in the marketplace This makes it very easy to integrate Modbus-compatible equipment into new or existing monitoring and control applications

2.4.3 RS-485 standard

In RS485 standard, data is transmitted via two wires twisted together also referred to as

“Twisted Pair Cable” The twisted pairs in RS485 give immunity against electrical noise, making RS485 viable in electrically noisy environments

RS485 at its core with 2 wires allows half-duplex data transmission This means data can be transmitted in both directions to and for devices one direction at a time By adding another 2 wires, making it a 4 wires system, it allows data transmission in both directions to and for devices at the same time, also known as full-duplex However, in

a full-duplex setup, they are limited to a master and slave communication where slaves cannot communicate with each other

Similarly, TX and RX refer to the transmitted signal and received signal respectively

It is also represented by the orientation of the triangles

Variably, this time both TX and RX have their own 2 wires for data transmission This means that data can be simultaneously transmitted and received between devices

2.5 Three-phase pump

2.5.1 Definition

A water pump is a hydraulic machine that receives energy from the outside (mechanical energy, electrical energy, hydroelectricity, .) and transfers energy to the fluid flow, thereby bringing the liquid to a certain height or move liquid through the pipeline system

2.5.2 Structure

The structure of the water pump consists of two main parts: the electric motor and the pump head

Electric motor includes:

- Motor cover: Protects the internal components of the electric motor

- Static part (Stator): The basic component of an electric motor

- Rotary Shaft (Rotor): Transmits motion through the pump head

- Fan: Cools the engine

- Bearing: Fixes the position of the rotor and allows the rotor to rotate

- Electrical panel: supply power to the motor

The pump head includes:

- Pump cover: Pump body, protects the hydraulic part of the pump

- Impeller: Creates and directs the movement of water inside the pump

- Pump Wheel: Converts the energy or motion produced by the impeller into pressure

- Mechanical seal: Prevents water from entering the engine

- Round seals: Seals between pump components

2.5.3 Operation principle

The water pump operates on the general principle of sucking all the air out of a pipe (creating a vacuum) causing the pressure in the pipe to drop to 0 At that time, atmospheric pressure presses on the water surface, causing the pressure to drop to zero The water in the tube rises

When the pump body and suction pipe are fully supplied with water, the machine will operate according to the push-pull process, this process of suction and push takes place continuously to create a non-stop flow to help transport water

2.6 Solenoid valve

2.6.1 Definition

A solenoid valve is an electromechanically controlled valve that eradicates the need for

an engineer to operate the valve manually Usually, solenoid valves are used whenever flow of media must be controlled automatically An increasing number of plants are taking advantage of the solenoid valve, as a variety of different designs are available, enabling the valve to be selected to suit the application in question

2.6.2 Structure

A solenoid valve is a control unit that is electrically energized or de-energized to allow for the shut-off or release of flow It is made up of two main parts: the solenoid; an electric coil with a movable ferromagnetic core in its center, and an iron plunger that is allowed to move through the center of the coil When the coil is energized, the resulting magnetic field pulls the plunger to the middle of the coil A spring is also required to return the plunger to its original position

Figure 2.6.1 Figure 2.6.2 When the solenoid valve’s iron plunger is in rest position it closes off a small orifice

An electrical current then runs through the coil, creating a magnetic field The magnetic field then places force on the iron plunger, resulting in the plunger being pulled towards the center of the coil opening the orifice This is what in turn controls the flow, allowing for the shut-off or release of media

2.6.3 Types of valve

There are three main solenoid valve technologies: direct acting, in-direct acting, and semi-direct acting type Each of these solenoid valves work in slightly different ways and are suited to different applications

Direct-acting solenoid valves – have the simplest working principle In a normally closed valve, the media flows through a small orifice which can be closed off by a plunger with a rubber gasket at the bottom In a direct acting solenoid valve, the plunger

is held down by a small spring made of ferromagnetic material An electric coil is positioned around the plunger and as soon as the coil is electrically energized, a

operating principle is the same in a normally open valve, except it works in the opposite way

The operating pressure and flow rate is directly related to the orifice diameter and the magnetic force of the solenoid valve Direct operated solenoids don’t require a minimum operating pressure or pressure difference either So, they can be used up to the maximum allowable pressure The lack of moving parts allows for very compact designs to be produced direct acting valves are available with Brass, Stainless Steel and Plastic bodied variants and a choice of seal materials making them suitable for most media types Because they don't normally rely on the use of very small (<1mm) internal holes or passageways direct acting valves can be more tolerant of small amounts of dirt

in the media than servo-assisted types

Indirect solenoid valves – operate differently to direct operated solenoids and use the differential pressure of the media over the valve ports to open and close Indirect solenoid valves need a minimum pressure differential of around 0.1 to 0.5 bar depending

on the size, and are separated by a rubber membrane, also known as a diaphragm The membrane in an indirect acting solenoid valve has a small hole which allows the medium to flow to an upper compartment The pressure and supporting spring above the membrane ensures that the valve remains closed Once the solenoid valve is energized, the pressure difference on both sides of the membrane allows media to flow from the inlet port to the outlet port

The operation of an indirect solenoid means they can only be used in one flow direction and are therefore suited for a high desired flow rate, including irrigation systems

Figure 2.6.7 Figure 2.6.8 The semi-direct acting solenoid valve – has the properties of both direct and indirect-acting solenoid valve Due to this it can operate from zero pressure and handle a large flow rate The design of the semi-direct acting solenoid valve is nearly the same as the indirect-acting solenoid valve It has a rubber membrane with a small orifice and pressure chambers on both sides of the membrane The only difference here is that the solenoid plunger is directly connected with the membrane When the solenoid gets energized, the plunger is lifted, and the material starts flowing Also, this causes a second orifice at the membrane which has a small diameter than the main orifice to open This creates a pressure drop at the chamber above the membrane, this also lifts the membrane The combined properties of both direct and indirect-acting solenoid valve result in the semi-direct acting solenoid valve to operate from zero pressure and handle relatively large flow rates

2.6.4 Installing

Solenoid valve is one of the most used valves in automatic control system It is favored

by users because it is cheap, simple to operate, convenient and reliable, which can directly receive switch signals of PLC or DCS Of course, only when it is used properly can the solenoid valve play its full role Here are some tips in the installation of solenoid valves for your reference

- First check whether the solenoid valve is consistent with the selection parameters, such as power supply voltage, medium pressure, pressure differential etc If the voltage of power supply is chosen wrongly, it will burn the coil Generally, the power supply voltage should meet the fluctuation range of rated voltage: AC +10%~-15%, or DC +10%~-10% Besides, the coil components should not be disassembled normally

- Generally, the installation of solenoid valve should ensure that the solenoid coil part of the solenoid valve is vertical upwards and the valve body horizontal Thus, it should be installed in the pipeline horizontal to the ground If the solenoid valve needs to be installed on an upright pipe due to space restrictions

or working conditions, please be informed in advance when ordering, otherwise, the solenoid valve may not work properly

- The solenoid valve is generally directional, so it cannot be installed upside down Usually there is a sign “→” on the valve body to point out the direction of the medium flow Therefore, the installation should agree with the direction of instruction “→”

- Try not to let the solenoid valve in energized state for a long time, so that it can easily reduce the service life of the coil or even burn the coil That is to say, the normally open and normally closed solenoid valve is not interchangeable

2.6.5 Applications

Common domestic and industrial solenoid valve applications include:

- Refrigeration systems use solenoid valves to reverse the flow of refrigerants This helps in cooling during summer and heating during winter

- Irrigation systems use solenoid valves with automatic control

- Dishwashers and washing machines use solenoid valves to control the flow of water

- Air conditioning systems use solenoid valves to control air pressure

- Solenoid valves are used in automatic locking systems for door locks

- Medical and dental equipment use solenoid valve to control the flow, direction, and pressure of the fluid

- Water tanks use solenoid valves to control the inflow or outflow of water, often

in combination with a float switch

- Car washes to control the water and soap flow

- Industrial cleaning equipment

2.7 Fountain nozzle

2.7.1 Function

A fountain nozzle is essentially an attachment which usually fits onto the top of a

the end of your garden hose, the fountain nozzle will convert a single jet of water into something far more impressive and interesting

Fountain nozzles are diverse and come in all shapes, sizes, materials, and different effects One can imagine how different fountain nozzles would look when playing, and equally important to decide what type of fountain nozzle one wants The primary function of a fountain nozzle is to make unique patterns of water overflow used in commercial and residential water features Fountain nozzles can be either plastic, brass,

or stainless steel and used according to one's needs, irrespective of the landscape and budget

2.7.2 Types of nozzle

Traditional single jet fountain nozzles are cylindrical tubes with one hole for water to come out The simplicity and functionality of the design make it worthwhile for household and recreational purposes It is the type of nozzle you may see in traditional hoses and sinks This style of fountain nozzle is also commonly seen on drinking fountains In water fountains, it can add style and sound to a pond

Multi-jet fountain nozzles are one of the most common styles to put on a water feature

It has a cylindrical shape with multiple circular holes on the head, like a showerhead This mechanism allows for water to spray out evenly throughout the holes If the exit holes are close together, the water will generally form one connected stream If the holes are further apart, the streams of water may remain separate

Figure 2.7.3 Figure 2.7.4 The geyser jet nozzle is like the cascade in that it creates a tall column of water However, the effect is a whiter, frothier jet of water The geyser nozzle combines water from the basin, a pipe, and air to make a splashing, powerful projection

Accordingly, these nozzles should be slightly submerged while mixing air and water simultaneously

An umbrella nozzle is also called a mushroom, water bell, or morning glory nozzle It

is a circular nozzle that faces upward in a small body of water The nozzle remains above water and ejects water smoothly and evenly around the entire circle The effect

is a transparent umbrella of water cascading in the air The unique result is enjoyable to the eye and makes a great addition to ponds and gardens

Figure 2.7.7 Figure 2.7.8

2.7.3 Applications

In the steel production line, nozzles account for a small proportion, but they play an important role and directly affect the quality of steel and determine the amount of consumption of certain substances such as water, bleaching acids, etc compressed air Some important applications of nozzles in the steel industry are: Steel billet cutting; Cooling billet, rolled steel; Rust removal, scraping; Dust suppression; Spray mist to suppress dust at ore crushers

Artistic fountain heads are beautiful and impressively shaped water spray devices, specialized for installation for fountain projects, artistic water music, decoration for small gardens, swimming pools, and pools fish Unlike ordinary fountains, artistic fountains can create vivid water designs such as mushroom caps, fan shapes, spheres, pine trees, calyx shapes, trumpet shapes, etc if cleverly designed and combined types

of sprinklers can create more impressive and attractive effects

2.8 TIA Portal software

2.8.1 Definition

TIA Portal, short for Totally Integrated Automation Portal, is an integrated software of many automation and electrical operations management software of the system Understandably, TIA Portal is the first automation software that uses the same environment/platform to perform tasks and control the system From designing, commissioning, operating, and maintaining to upgrading automation systems, the TIA Portal saves engineers time, cost, and effort SIMATIC STEP 7 in the TIA Portal is the software for the configuration, programming, testing, and diagnosis of all modular and

PC-based SIMATIC controllers and includes a variety of user-friendly functions More flexible, faster, and more productive: Innovative simulation tools, seamlessly integrated engineering, and transparent plant operation work perfectly together in TIA Portal The new options benefit system integrators and machine builders as well as plant operators, making TIA Portal your perfect gateway to automation in the Digital Enterprise

2.8.2 Components of software

TIA Portal software is developed by Siemens with many components to help users manage and program PLC, HMI effectively Components included in the TIA Portal suite:

- Simatic Step 7 professional and Simatic step 7 PLCSIM: PLC simulation and programming solution S7-300, S&-400, Simatic S7-1200, Simatic S7-1500

- Simatic WinCC Professional: Used to program the HMI display, and SCADA interface

- Simatic Start Driver: Programmed to configure Siemens

- Sirius and Simocode: Flexible configuration and diagnostics

- Single- and multi-axis motion control with Scout TIA support The full data Simatic Robot library allows users to set up configurations and systems quickly