Introduction Learning Outcomes - EAT240 - Automation for Manufacturing Coursework Assignment Control System for Mixing Tanks This coursework exercise will provide you with the opportunity to demonstrate the skills you

will develop throughout the module. Specifically, the following learning outcomes will be assessed: LO2 - Design integrated automated systems using controllers, sensors, and actuators. LO4 - Design and implement an automated system to solve a range of problems including the control of common actuators. LO5 - Design and test typical programming solutions for use with automation systems. Practical Design Exercise The assessment is a practical design exercise worth 50% of the module mark. You will be required to work individually to develop a control system for an industrial application. Scenario, Scenario - A manufacturing company has recently installed a new paint line. The paint line (see figure 1) can mix different colours of specialist paint to a set temperature. After the mixing process has been completed the tank will empty to fill a batch of tins. The completed batch will then be transferred to a labelling process before final transfer to a warehouse, ready to be shipped to the customer. Task - Your company has been contacted to tender for the control system for the paint mixing and packaging line. The project manager has decided to utilise your skillset and you have been tasked with individually designing a PLC program for the machine that as a minimum meets the basic system requirements. As part of the tender process, you must submit the appropriate documentation to an industrial standard, including sequential flow charts, machine drawings and PLC programs. Note: Please note all work should be completed on an individual basis and you will need to carry out a face-to-face demonstration of your finished programme in order to complete the assessment. Task 1 - System Control, The system shown in figure 1 is to be controlled by the PLC. The PLC will perform the following functions using the sequences and basic requirements listed below, Sequence 1 – (Paint A) is heated to a temperature of 30 degrees and mixed for a 2-minute cycle. Sequence 2 – (Paint B) is heated to a temperature of 60 degrees and mixed for a 5-minute cycle time. A) - Basic System Program Requirements (to be used as guidance), Step 1 - Upon activation of the system ready push Button, the system will be made ready to use - only if the conveyor, heating elements and mixing tanks are switched off. This will also be indicated by a red "System ready" light. The system must have an emergency stop to shut down the full system. Note: Emergency stop should stop the full system from working until reset. Step 2 - When the "system ready" light is on, the process will start after a 10 second delay when selected by the machine operator and the conveyor will then move the empty tins to the appropriate filling station. Step 3 - Once the batch of tins is present at the filling stations and the low-level sensor is activated, the fill pumps are energised to allow the filling of tank A or B until the high-level sensor is activated. Step 4 - When the tanks are full, the mixing and heating cycle will start. After the mixing cycle is complete, there will be a delay for 5 seconds to allow the paint to settle and then the tank will empty until low level sensor is activated and the batch is complete. Note - You must ensure that if there is a loss of power the mixing cycle does not exceed the paint cycle time. Step 5- Once the batch has been completed, energise conveyor motor and transfer to the warehouse process. Note: The number of batches must be counted in and out of the warehouse location and once 50 batches have been made, the program will prevent the operator from making any more, until the system has been reset. EAT240 PLC Design Notes (20 Marks) The customer has asked for a comprehensive a set of design notes for the PLC program based on the required functionality described above. This may include: ● Flowchart or Sequential Function Chart 1/0 list Variable list Comments on the purpose of each rung Pneumatic/Hydraulic Drawings PLC/HMI Program (20 Marks) You will create your PLC program individually using your design notes. You can refer to the to the following documentation which is available through the CCW software and on Rockwell Automation website (details in the lab guides): ● CCW programming manual Micro820 hardware manual CCW quick start guide Actuator/Sensor Evaluation and Selection (10 Marks) Based on your experience of developing the PLC Program consider how the machine could be improved, you may wish to consider performance, efficiency, reliability, or maintainability as part of your assessment. You should refer to the actuators and sensors which are used and choose at least 2 actuators and sensors that could be used to improve the system, providing a description and evaluation of each type. You will present a brief (max 4 pages) report which summarises the evaluation, supported by appropriate references to your earlier work and any relevant technical documentation. Engagement with Lab Sessions While there are a number of elements to this assessment much of the work is based on the activities that you will carry out online and during the laboratory sessions. Therefore, if you engage with these activities you will greatly enhance your chances of achieving a good mark. After each session you should try to think about how the material covered could contribute to the assignment and make a note of this to support the design exercise. The laboratory sessions will involve the use of the Rockwell Micro 820 PLC. Any submission for alternative devices e.g. Arduino will not be accepted. Importance of Design One of the most important themes in this module is the importance of design. It is important, therefore, that you allow adequate time to design your program. If you fail to do so you will not only jeopardise the design elements of the coursework, but you will also make it extremely difficult to score well for the coding activities. Avoiding Accusations of Plagiarism Any code you write must be entirely your own. You may bring listings into the coding sessions but if these have been sourced from another source e.g. a text book or the internet, then this must be fully acknowledged using comments which clearly and unambiguously identify the extent of the code involved (e.g. by labelling the start and end of the section in question) and the source. You should also ensure that all work in the written submissions is your own and correctly referenced. Where you draw on references you should ensure that you clearly explain their relevance to your own work. If you are unsure on the correct way to reference any material, please ask or refer to the guidance available via the University Library Website: http://library.sunderland.ac.uk/find-resources/referencing/ Presentation of Work Presentation of work is of critical importance. The elements being submitted electronically should be typed and clearly formatted making appropriate use of headings and subheadings. Your design notes for the PLC program may be handwritten or typed but MUST be clear and legible.