Question

Design a system that shows a simplified automatic car wash system with the following operating conditions:

- Water level needs to be maintained at water level (> Lower limit and < Upper limit ) at all times to ensure the water pressure is sufficient for the wash cycle.

- 2 Possible errors:

- Water level exceeds upper limit or water level falls below lower limit

- Car move away while washing process is ongoing

- System shall stop if the water level falls out of normal range for a specific duration ( example. 30 secs)

- Green indicator will turn on when car wash is in progress(system is running) and red indicator will turn on when the system stops

- Start/ stop push button is used to turn on / off the system

- Roller and spray valve should turn on when car presence is detected and the system is running with normal water level. The washing cycle should last for 5 minutes

- Buzzer will turn on when there are errors. When the buzzer is triggered, the buzzer frequency should be programmed in such as a way that the operator can differentiate between water level errors or error caused by car moving away during the wash cycle.

- A counter is used to count the numbers of cars washed by the system.

* Assuming the water level sensor provides a 0-10V output voltage corresponsed to the water level of 0-100%.

It should include

- Information on sensors, actuator, motors, relays used in designing the system

- All wiring circuits

- Input/output table

- PLC configurations and ladder diagrams

- Any process improvement proposed/ implemented

- Database table which include the necessary data( minimum 5 data) to be uploaded to the cloud

- Suggestion of possible data analysis / monitoring for this system

Answer 1

PRE WASH SECTION

BRUSHING

CLEAN WASH SYSTEM

DRYING SECTION

EXIT

BLOCK DIAGRAM

INPUT INTERFACING CIRCUIT DIAGRAM OF IR WITH HYBRID DCS

Output interfacing circuit diagram of DC Motor, Solenoid & Dryer with Hybrid DCS:-6.1 Output interfacing circuit diagram of DC Motor, Solenoid & Dryer with Hybrid DCS:-

Working of System

Input-IR sensor:

· When car comes on IR-sensor, sensor sense and conveyor starts moving with the help of motor (M2) until it will reach to the next IR sensor section

· As car reached to next ir section then entry gate start to open for 2sec

Pre-Wash Section

· As the car reaches in pre-wash chamber, shampoo water falls on the car by opening valve (V1).

· Valve will remain on for 5 sec. After 5sec. valve will close automatically.

· Again conveyor starts moving until it will reach to the next ir sensor section(Brushing section)

Brushing Section

· As the conveyor stops vertical brushes starts brushing the car for 10sec. and stop.

· Again conveyor starts moving until it will reach to the next ir sensor section(Clean wash section)

Final Wash Section

· Valve (V2) gets open for 5 sec. and get closed.

· Again conveyor starts moving until it will reach to the next ir sensor section(Drying)

Drying

· Start dryer for 10 sec. and stop.

Exit

· After drying stage completion open exit gate with the help of motor (M6) for 2 sec. and stop.

· Again conveyor starts starts moving until it will reach to the next ir sensor section.

· Close the gate (M6)

LADDER DIAGRAM OF PROJECT