Proceedings of 4th RIT Post Graduates Conference (RIT PG Con-18)

NOVATEUR PUBLICATIONS
JournalNX- A Multidisciplinary Peer Reviewed Journal (ISSN No:2581-4230)
April, 13th, 2018
AUTOMATIC LADLE CONTROL WITH JOB DATABASE USING PLC-SCADA
Miss. Najbin Chandso Momin Dr. Mahadev S. Patil
Department of Electronics and Department of Electronics and
Telecommunication Engineering, Telecommunication Engineering,
Rajarambapu Institute of Technology, Rajarambapu Institute of Technology,
Rajaramnagar, Sangli (M.S.), India Rajaramnagar, Sangli (M.S.), India
[email protected] [email protected]

Abstract-The main objective of the proposed system is to heavy workload to the worker, it is very difficult to carry
introduce automatic ladle control pouring system with job tenders, difficult to carry tenders near to mold, when
database using PLC-SCADA. Factory manufacturing molten metal takes from a furnace then after few second
number of various types of products by the casting
pour into the mold it is a very difficult task. So, to
process. Now a days this casting process is manual. This
manual process has many disadvantages. The aim of the
overcome disadvantages of the both pouring systems we
project is to reduce human hazards, minimizing pouring develop a system, automatic ladle control pouring
time, minimizing spillage loss in order to achieve higher system with job database using PLC-SCADA.
quality product. The purpose of this dissertation work is to
Keywords: Casting, Human hazardous, Cost effective, Automize the system using a PLC. For implementing this
Higher productivity, Quality casting system weight and metal is required. For reducing
I. INTRODUCTION supervisor work, we are going to implement a database
The foundry is a factory which produces casting of using HMI-Human Machine Interface. All the jobs
metal. Casting is a manufacturing process in which a completed in one year will be saved in personal
liquid material is usually poured into a mold, which computer daily.
contains a hollow cavity of the desired shape, then the II. LITRATURE SURVEY
liquid material is allowed to solidify that solidify part is Yuan P et.al discussed the work related to the
known as casting which is forced out of the mold the temperature of molten metal which is used for casting. In
entire process. But all work in foundries is processed ladle furnace, the prediction of the liquid steel
manually. The main purpose of this Project is to suggest temperature is always a hot topic for the research.
automatic ladle control a job database using the plc- Normally the molten metal temperature cannot be
scada system rather than manually pouring system. The measured continuously, making it very difficult to realize
manual process is time consuming. For creating a job, precise controlling. They developed a new temperature
first metal is converted in molten from then pour that module which measures the accurate temperature of the
liquid form of metal in ladle the furnace. At that time molten metal or steel. There are a number of parameters
required temperature of molten metal was 14000C- which are hard to obtain, so system is developed to
15000C. The capacity of the small ladle is 60-70 Kg. with improve the precision of mechanistic models. Intelligent
the help of the two-worker ladder is carried to the mold methods have been used for predicting the temperature
then pour the liquid form of metal in it. Due to this of the liquid steel in ladle furnace. The precision of liquid
manual system, industries and foundries faces number of steel temperature model is satisfying in industrial
problems. This system is time consuming and frequent production of ladle furnace. [1]
reheating of metal is also risky. The casting molten metal Prashant Tiwari et.al discussed the
has very high temperature; it is hazardous for workers semiautomatic pouring system. The aim of this paper is
to work in this high temperature. It may cause defects in to reduce human intervention, minimize pouring time &
casting and due to over pouring cost increases. Because to achieve higher quality of casting. In this paper
of this high temperature pouring may occur over pour or researcher have discussed the present system of the
short pour. Over pouring means more molten metal pour casting or pouring. There are a number of problem
in the mold than required pour. Less pouring means less workers face in the present system, so semiautomatic
molten metal pour in the mold than required. Due to pouring system is discussed. Now days the actual
short pour and over pour not only increases faults in process is labors pour the molten metal from the furnace
casting but also reduces the quality of the product. into a small ladle, then two labors carry the small ladle
Number of times because of the laziness of the workers, near to the mold. Molten metal has a temperature near
companies/industries faces more loss. One of the losses about 16000C. So this work is also risky, using different
is spillage loss. Production of series of defective, sensors they have discussed the semiautomatic pouring
unacceptable products is rejected. It is necessary to system. [2]
remove this entire drawback. Xiojun Wang et. al studied present accurate
To overcome all disadvantages in manual process control of the steel temperature during ladle furnace
one system is already developed that is mono rail method and data driven modelling algorithm are
system. In this process molten metal track in tundish combined for obtaining a precise prediction model is
from the furnace. The capacity of that tends to be 600 Kg presented on the basis of the proposed pruned bagging
and then this tends on the mono rail which is carried by method. This method uses negative correlation learning
manual process and then tilt is also by manually. This to prune, so the result of this proposed ensemble-based
process also has a number of disadvantages. These are
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 Proceedings of 4th RIT Post Graduates Conference (RIT PG Con-18)
NOVATEUR PUBLICATIONS
JournalNX- A Multidisciplinary Peer Reviewed Journal (ISSN No:2581-4230)
April, 13th, 2018
steel temperature predictor is able to provide a precise multiple process of digital and analogue inputs and
prediction with high accuracy and reliability. [3] outputs. There are different types of PLC’s like Siemens,
Huang G B et.al discussed the use of least square Allen-Bradley, Delta, mitshubishi, Omron etc. fig shows
support vector machine (LS-SVM) and proximal support delta PLC. This PLC has 2-CH 12-bit analog voltage or
vector machine (PSVM) in the binary classification current input and 2-CH 12-bit analog voltage or current
application. These both methods cannot be used in output are bipolar. It has 10-point PLC. That means total
regression and multiclass classification application input and output pin is 10. Because of the following
directly. This paper also shows that both LS-SVM and features select the delta PLC.
PSVM can be simplified further. Unified learning
framework of LS-SVM, PSVM and other regulation
algorithm referred to extreme learning machine can be
built. ELM also works for generalized single hidden layer
feed forward networks, but hidden layer in ELM need
not be tuned. [4]
III. SYSTEM DESCRIPTION

Weight
sensor Motor
PLC

Metal
PC
sensor-1

Fig.2: Delta DVP-10SX PLC

Metal HMI Features of Delta PLC:
sensor-2  4-Digital input, 2-Digital output.
 2-Analog input, 2-Analog output.
 Power supply voltage -24Vdc.
Fig.1 - Proposed Block Diagram  Input current-5mA.
 Responding time – 10 ms.
IV. SYSTEM COMPONENTS  2-CH analog voltage/ current input and output are all
bipolar.
The system components are divided into two  Built in 2-digit 7-segment display corresponds to
categories. Software and hardware, they are classified as internal resister directly to display PLC station or user-
follows. defined code.
Software components  Expandable input/output.
WPL soft 2.45  Compact in size.
WPL soft 2.45 is PLC programming software  Input/output point indicators.
this operating system is Windows XP/Vistal/7(32-  Status indicator: power, run, ERROR, BATLOW.
bit/64-bit)/8/10 (64-bit). DVP series is supported in this  Ladder, SFC, instruction language.
software. Weight sensor:
DOP Soft 2.00.06 A weight sensor that the change a load acting on it,
DOP Soft 2.00.06 is used for HMI. HMI means into an electronic signal. This electronic signal can be
Human Machine Interface. converted in voltage, current or frequencies. This
conversion depends upon which type of weight sensor
Hardware components and which circuit is used. The filling of the mold or cavity
PLC (Programmable Logic Controller) in the casting is determined by weight sensor. This
DVP 10 SX 11 R weight sensor detects how much molten metal present
DVP - Series name in the ladle. When weight of the molten metal in ladle is
10 - Input/output points (4DI+2DO+2AI+2AO) not sufficient then ladle will be locked therefore we
SX - SX Series cannot tilt the ladle for filling mold.
11 - DC Power input Metal sensor:
R - Relay A metal detector is an electronics device which
PLC means Programmable Logic Controller, it is a generates an AC current that passes via a coil generating
digital computer used for automation of industrial an alternating magnetic field. When a part of the metal is
electromechanical processes. PLCs are used in many near to the coil, eddy current will be produced in the
machines, in many industries. PLCs are designed for metal objects and a magnetic field is generated. This

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 Proceedings of 4th RIT Post Graduates Conference (RIT PG Con-18)
NOVATEUR PUBLICATIONS
JournalNX- A Multidisciplinary Peer Reviewed Journal (ISSN No:2581-4230)
April, 13th, 2018
sensor can also be used to detect the presence or
absence of the object/ladle. We choose inductive
proximity sensor which has 0.5-250mm sensing
distance. One important features that is when it operates
in harsh environment then very little negative effect.
High sensitivity, reliability. Very good about ruggedness.
Its operating voltage range is 6-40 Volt DC. This metal
sensor has also inexpensive.
HMI (Human Machine Interface):
There are different names of HMI. Those names are
User Interface (UI), Operator Interface Terminal (OIT),
and Man Machine Interface (MMI). It is a hardware and
software solution for exchanging information between Fig 4: Instruction list mode
machine and human operator. HMI enables control,
management of device processes and can range from
simple inputs on the touch display to control panels for
highly complex industrial automation system.
Specification:
 Display type: 7” TFT LCD (65535 colours).
 Resolution: 800*480 pixels.
 Display size: 154.08*85.92.
 MCU: 32-bit RISC Micro-Controller.
 NOR flash ROM: 128MB.
 SDRAM: 64Mbytes.
 Backup Memory: 16 Mbytes.
 Operating range: 24V.
Motor:
An electric motor is an electrical machine that Fig 5: Output window of the program
conversion of electrical energy into mechanical energy.
The Motor will be used in this project to tilt the steering
for filling the mold of casting. We will use stepper motor
because of this feature. Stepper motor is stable. This
motor works also the position transducer. This motor is
inexpensive related to the other motors. The main
purpose of use of this motor is safe. If anything is breaks
the motor will be stops. This motor has long life. It has
excellent low speed torque. It can be drive many loads
without gearing. It has excellent repeatability. It has
automatic returns to the same location accurately.it has
also self-overloading. Fig 6: Interfacing between PLC and HMI
PC:
For storing all data PC will be used. Because of this
we can check any data of any date.
V. RESULT

Fig.7: Interfacing between PLC and HMI

Fig 3 shows ladder diagram for basic program, fig 4
shows instruction list mode, fig 5 shows output of the
program in delta WPL soft 2.45. This is a result of
software.
Fig.6 & 7 indicates interfacing between Delta PLC and
HMI. Fig.6 indicates ladle is locked that means molten
metal is not sufficient for required one mold. Fig.7
indicates ladle is unlocked that means molten metal is
Fig 3: Ladder diagram for basic program sufficient for required one mold. These figure also
indicates how many mold preparing.

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 Proceedings of 4th RIT Post Graduates Conference (RIT PG Con-18)
NOVATEUR PUBLICATIONS
JournalNX- A Multidisciplinary Peer Reviewed Journal (ISSN No:2581-4230)
April, 13th, 2018
CONCLUSION
Before the development of this system all the
process were carried out manually by giving this human
being were need to carry molten metal which is very
high temperature so automation of this process is
needed which is done here. The present system is to
reduce time; decreases work effect of labor and
eliminate the hazards to employees. It is a self-
compensating and automatic system, which repeatedly
and accurately fills the mold. This system increases
efficiency and productivity to produce high quality
casting. This system reduces the spillage loss. The
present work reduces the hazardous to the worker.
VI. REFERENCES
[1] Lv W, Mao Z, Yuan P, Jia M, “Pruned Bagging Aggregated Hybrid
Prediction Models for Forecasting the Steel Temperature in Ladle
Furnace”, Journal of Steel research, Volume 85, Issue 3, 2014, pp. 405-
414.
[2] Prashant Tiwari, Raj Koyhwale, Prashant Yadav. ”Semi-Automatic
Pouring System”, International Research Journal of Engineering and
Technology, Volume 04, Issue 04, April 2017.
[3] Xiaojun Wang, “Ladle Furnace Temperature Prediction Model Based
on Large-scale Data with Random Forest”. IEEE Journal of Automatic
Sinica, Issue: 99, 2017, pp. 1-5.
[4] Huang G B, Zhou H, Ding X, Zhang R, “Extreme Learning Machine for
Regression and Multiclass Classification”. IEEE Transaction on System,
Man, and Cybernetics part B.Cybernetics, 2012, Volume.42, Issue 2, pp.
513-529.

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