PIC 16F877A NURULAFIZA BT RAMLI

Transcription

1 AN ELECTRONIC CLOCK DISPLAY USING OMRON PLC TRAINER AND PIC 16F877A NURULAFIZA BT RAMLI This report is submitted in partial fulfillment of the requirements for the award of Bachelor of Electronic Engineering (Computer Engineering) With Honours Faculty of Electronic and Computer Engineering Universiti Teknikal Malaysia Melaka April 2009

2 UNIVERSTI TEKNIKAL MALAYSIA MELAKA FAKULTI KEJURUTERAAN ELEKTRONIK DAN KEJURUTERAAN KOMPUTER BORANG PENGESAHAN STATUS LAPORAh' PROJEK SARJANA MUDA I1 I1 TajukProjek Sesi Pengajian AN ELECTRONIC CLOCK DISPLAY USING OMRON : PLCTRAINERANDPIC 16F877A : / Saya... NURULAFIZA BT RAMLI..... (HURUF BESAR) mengaku membenarkan Laporan Projek Sarjana Muda ini dishpan di Perpustakaan dengan syarat-syarat kegunaan seperti berikut: 1. Laporan adalah hakrnilik Universiti Teknikal Malaysia Melaka. 2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan laporan ini sebagai bahan pertukaran antara institusi pengajian tinggi. 4. Sila tandakan ( d ) : SULIT* (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972), TERHAD* (Mengandungi maklumat terhad yang telah ditentukan oleh organisasiroadan di mana penyelidikan dijalankan) TIDAK TERHAD Alarnat Tetap: Lot 36 Kg. Sg. Deraka, Jalan Tanjung Lumpur, Kuantan Pahang Darul Makmur * Disahkan oleh: (COP DAN TANDATANGAN PENYELIA) FARlD ARAFAT BIN AZlDlN Pensyarah Fskutti Kejuruteraan Elektronik Dan Kejuruteraan Kornpute~ Universiti Teknikal Malaysta Melaka (UTeLl) Karung Berkunci No 1752 Pejabat Pos Durian Tunggal Durian Tunggal. Melaka Tarikh: I...30 April Tarikh:...30 April

3 "I hereby declare that this report is the result of my own work except for quotes as cited in the reference" Signature :... Author Date : 30 APRIL 2009

4 "I hereby declare that I have read this report and in my opinion this report is sufficient in terms scope and quality for the award of Bachelor of Electronic Engineering (Computer Engineering) With Honours" Signature Name QbP-P : c.. : MR FARID ARAFAT BIN AZIDIN. Date : 30 APRIL 2009

5 Special dedication to my beloved father and mom, my entire sibling and my kind hearted supervisor Mr. Farid Arafat bin Azidin, and my dearest friends.

6 ACKNOWLEDGEMENTS I would like to extend my sincere gratitude to my supervisor, Mr. Farid Arafat bin Azidin, for her assistance and guidance toward the progress of this thesis project. Through the year, Mr. Farid Arafat bin Azidin has been patiently monitoring my progress and guided me in the right direction and offering encouragement. Obviously the progress I had now will be uncertain without his assistance. My special appreciation and thank to my friend Mohd Firdaus and Noor Roha for their invaluable assistances towards this thesis project. I also would like to thank to my family especially to my parents without their support and understanding this would not have been possible.

7 ABSTRACT The project aim was to a built an electronic board which detect signal from Omron PLC trainer. A programmable logic controller (PLC) in an operating system such as a machine includes a software development. The hardware part was based on a simple circuit on Printed Circuit Board (PCB) with LCD display. The signals from programmable logic circuit were transferred to PCB board as a time clock signal. PIC 16F877A microcontroller was used as interface in order to display time clock on LCD display. The electronic board also was designed with the voltage regulator to step down the voltage, 24V form PLC to 5V. The software development started with the flow chart, ladder diagram for PLC and finally, the software was written in C language and implement on the PIC. As the result, whenever the PLC counting and change the signal (clock), the LCD display will shown the output simultaneously with the PLC.

8 ABSTRAK Tujuan utama projek ini adalah membina satu litar elektronik yang marnpu mengesan signal yang dihasilkan oleh Omron PLC. Litar eleckronik ini terdiri daripada litar PCB dan paparan LCD Isyarat yang di hasilkan dari PCB board akan dihantar ke litar untuk menghasilkan keluaran masa di paparan LCD. PIC16F877A akan digunakan untuk menjana keluaran isyarat masa di paparan LCD. Litar elektronik ini juga akan dilengkapi dengan litar voltage regulator untuk merendahkan nilai voltage dr 24V kepada 5V. Pembangunan perisian akan dimulakan dengan membina carta alir, gambarajah ladder dan di aplikasikan ke dalam PIC dalam bentuk kod. Sebagai keputusannya, apabila terdapat perubahan isyarat dari PLC maka isyarat yg diterima serta di hantar kepada paparan LCD secara serentak.

9 CHAPTER TITLE PROJECT TITLE DECLARATION 1 DECLARATION 2 DEDICATION ACKNOWLEDGEMENT ABSTRACT ABSTRAK TABLE OF CONTENT LIST OF TABLES LIST OF FIGURES LIST OF SYMBOLS LIST OF APPENDIX PAGES iv v vi vii... Vlll ix xii xiii xv xvi I INTRODUCTION 1.1 Project Introduction 1.2 Objective Project 1.3 Problem Statement 1.4 Scope of Project 1.5 Methodology 1.6 Thesis Outline

10 I1 LITERATURE REVIEW 2.1 Definition PLC Features of PLC Ladder Logic Discrete Input and Output System 2.2 Microcontroller Identifying suitable Microcontroller PIC 16F877A Pin Description Introduction to CCS C Compiler Introduction to Proteus VSM LCD Display I11 METHODOLOGY 3.1 Flow chart 3.2 Project Planning Planning Work Flow 3.3 Software Development Introduction to CX-Programmer Setting for Program Ladder Diagram Languages System for the Content Transfer to PLC PLC Work Online Simulator 3.4 Hardware Development Voltage Regulator PIC 16F877A and LCD Display

11 IV RESULTS 4.1 Result Simulation Ornron PLC 4.2 Result Simulation PIC 16F877A Schematic ISIS Professional Program Code at CCS C Compiler Win PIC Programmer Voltage Regulator Voltage Regulator Etching at Positive PCB Board 4.3 Overall Result Signal from Ornron PLC Trainer Output LCD Display Output An Electronic Clock V DISCUSSION AND CONCLUSION 5.1 Conclusion REFERENCES

12 xii TABLE LIST TABLE TITLE PAGES 2.1 PIC 16F877A 110 Pin Discretions 4.1 Output of PLC 4.2 Counter of PLC 4.3 Timer of PLC

13 ... Xlll LIST OF FIGURES FIGURES TITLE PAGES Device of PLC A Connection of Rung A symbol of discrete output system Von-Neumann Architecture Harvard Architecture PIC 16F877A PIC 16F84 Microcontroller pin layout LCD Display Flow Chart of project methodology CX-Programmed Device and Network Type Simulation PLC Contact and Coil Timer Header Timer Bit and Value Component in Proteus Schematic Diagram PIC 16F877A CCS C Compiler Mnemonics Code LCD Display Win PIC Programmer Simulation Voltage Regulator 7812 Circuit Voltage Regulator 7812 Simulation Voltage Regulator 7805 Circuit Voltage Regulator 7812 and 7805 Etching circuit LCD Display

14 4.9 Etching Circuit Voltage Regulator 4.10 Troubleshooting Signal from PLC 4.11 Signal Generator 4.12 Circuit PIC 16F877A and LCD Display 4.13 Final Circuit

15 LIST OF SYMBOLS PLC - Programmable Logic Controller PIC - Peripheral Interface Circuit I/O - Input and Output LCD - Liquid Crystal Display

16 LIST OF APPENDIX NO TITLE PAGES A B LADDER DIAGRAM FOR CX-PROGRAMMER DATASHEET PIC 16F877A

17 CHAPTER I INTRODUCTION 1.1 Project Introduction Programmable logic controllers (PLC) have gained a very strong position in the industrial automation field. The growing complexity of the applications of PLC strongly depends on programmers and maintenance personnel. Hence, PLC education is a great demand nowadays. Programmable logic controllers (PLC) were originally design to control processes that required a sequence of events to be follow. Today, PLCs have advanced to the stage of being incorporate in SCADA (Supervisory Control and Data Acquisition) systems, continuous control systems. In industry, there are several manufacturers of PLCs, most of the instruction formats of PLC may not the same for different brands, but the hardware structures and programming concepts are very similar. For this project, the PLC was used to generate time clock and monitor the functional of electronic device. The signal from the PLC will be integrated at an electronic board, which is containing voltage regulator, LCD display and PIC 16F877A. In order to display the clock, PIC 16F877A was used to receive and analyze signal from PLC. This system provides a user friendly graphical interface and allowing analysis of PLC program and implemented in the real time simulation.

18 1.2 Objective of Project The main objective of this project is to design an electronic board with the capability to detect the signal from PLC and generate output time clock at LCD display by using PIC 16F877A within the required timeline and also to develop programming code based on PIC based system to support application of LCD display. 1.3 Problem Statement In the virtual PLC, the program is written using the Relay Ladder Language and supported by the programming editor. In run mode, the PLC makes its simulation of the ladder program based on its input and the program and displays the output. However, the output that has been generated was not easy to identify since the PLC just give the output by shown it based on the lightning of button output. In order to apply the application on PLC, it is needed to make sure PLC can be a user friendly system so that user can analyze the output easily. Therefore, for this project, as we know PLC can generate time clock however, it did not provide any display system for the user. Hence, it is necessary to integrate the PLC with other display system that is LCD display. In order to display using LCD display it is use PIC 16F877A as it interface to receive the signal from the PLC. In addition, the communication between PLC and PIC is a new innovation part in the industry since, people can see the growth in the technology if the two different technology was combined. Hence the complexity of the design can be develop and improve the features of the technology.

19 1.4 Scope of Project I. Literature study on the PLC program to identify how to use CX-program and develop ladder languages foe generate time clock. 11. Study the signal generated from PLC based on Ladder Programming Literature study on the Proteus VSM 6.0 to know how to use PIC 16F877A. IV. Study on Proteus VSM 6.0 to understand the application of PIC to display output by using LCD display. V. Develop and analyze the program efficiently in C programming language and by using ISIS 6 professional. VI. Design, and built an electronic board which can detect signal form Omron PLC trainer and can display the output at LCD display by using PIC 16F877A. VII. Integrate between the hardware and software after all design completed.

20 1.5 Methodology Phase1:- Identify the problem statement, which is how to generate time clock by using Omron PLC trainer and how to display the clock at LCD display by using PIC16F877A. Phase2:- Make a literature review for the project system including study about the component that will be use, their characteristic and understand deeply about the circuit and how it operates and analyze the datasheet of component involved such as (PLC, voltage divider, PIC and LCD display). Phase3:- For this phase, it called as software development, where involve analyze and study to design a ladder diagram by using CX-program to generate time clock and simulation PIC 16F877A by using Proteus VSM 6.9 to display the output at LCD display. Phase4:- For this phase, it called as hardware design. There are two phase for hardware design, which is Voltage regulator's circuit,pic 16F877A and LCD's circuit. All components must have extra features to make sure the troubleshooting circuit can be done easily.

21 Phase5:- For this final phase, it called performance test. In this phase, the software part and hardware part need to be combining together to get the result and to achieve the objective of project. The final results is then being compared with the theoretical. After that, the circuit that already constructed will be tested its functional, ability & weakness. If there is any error detected, the troubleshooting process will be done in order to make sure the circuit is well functioning. 1.6 Thesis Outlines This thesis consists of five chapters. The following chapters are the outline of the implementation of an electronic board which can detect signal form PLC to generate time clock and display the output at LCD display by using PIC 16F877A. Chapter I Will discuss briefly the overview of this project such as introduction, objectives, methodology and thesis outlines. Chapter I1 Contains the research and information about the project on several important concepts of ladder diagram on PLC, C-programming language on PIC 16F877A, technology and tools in the study. Every facts and information, which found through journals or other references, will be compared and the better methods have been chose for the project.

22 Chapter 111 Includes the detail about designing and programming to generate time clock system by using PLC and to display the output at the LCD display. Simulation results, analysis, observation and discussion of the performance to generate time clock technique are presented in. Chapter IV Includes the detail about the hardware design involved schematic diagram, PCB layout, components required and working principle for each circuit especially for circuit PIC 16F877A and LCD display. Chapter V Describes more about the discussion, and project findings. The result is then presented in figures or plotted graph. This chapter also discuss about the conclusion of the project and the future recommendations.

23 CHAPTER I1 LITERATURE REVIEW This chapter contains the research and information about the project on several important concepts of ladder diagram on PLC, C-programming language on PIC 16F877A, technology and tools in the study. Every facts and information, which found through journals or other references, has been compared and the better methods have been choosing among them 2.1 Definition of PLC A Programmable Logic Controller (PLC) also referred to as programmable controller. It is the name given to a type of computer commonly used in commercial and industrial control applications. PLC have been gaining popularity on the factory floor because of the advantages they offer such as: a) Cost effective for controlling Complex system. b) Flexible and can be reapplied to control other system quickly and easily. c) Computational abilities allow more sophisticated control. d) Reliable components make these likely to operate for years before failure.

24 e) Troubleshooting aids make programming easier and reduce downtime. PLC is different from office computers in the types of tasks that they perform and the hardware and software they require performing these tasks. While the specific applications changeable widely, all PLCs monitor inputs and other variable values and make decisions based on a stored program, and control outputs. The basic operation and elements of a PLC is including input models (points), a central processing unit (CPU). Output models (points) and a programming device. For the input models of PLC it is depends upon the types of input devices used. Some of the input models respond to digital input (discrete inputs) and other input models respond to analog signals. The primary function of a PLC circuitry is to convert the signal provided by these various switches and sensor into logic signal that can be used by the CPU. The CPU evaluates the input, output, and other variables and executes as a stored program. The CPU sends signals to update the status of the output. Output modules will convert control signal from the CPU into digital values that can be used to control a various type output devices. While the programming device is used to change the PLC's program, monitor and change stored values Features of PLC The main difference from other computers is that PLC is armored for severe condition such as dust, moisture, heat, cold and ext which have the facility for extensive input/output (I/O) arrangements. These connect the PLC to sensors and actuators. PLCs read limit switches, analog process variables such as temperature and pressure and the positions of complex positioning systems. On the actuator side, PLCs operate electric motors, pneumatic or hydraulic cylinders, magnetic relays or solenoids, or analog outputs. The input/output arrangements may be built into a simple PLC or the PLC may have external 110 modules attached to a computer network that plugs into the PLC. PLCs were invented as replacements for automated systems that would use hundreds or