Automation

This project, developed entirely within the Siemens Totally Integrated Automation (TIA) Portal, demonstrates the automation of a bottle filling process. It integrates a SIMATIC S7-1200 PLC program with a SIMATIC HMI (Human-Machine Interface) to create a complete control and visualization solution. The system is designed to manage the level of a main supply tank and sequentially fill bottles as they pass along a conveyor.

• PLC Programming in Ladder Logic (LAD): The core control logic is implemented on a Siemens S7-1200 CPU. The program, written in Ladder Logic, manages the entire process sequence using standard instructions such as latches (SR blocks), timers (TON), counters (CTU/CTUD), and comparators. Key logic sections include system start/stop control, automatic filling and level maintenance of the main reservoir, conveyor belt movement, and the timed dispensing of liquid into bottles.
• HMI Design and Visualization: A graphical user interface was designed for a SIMATIC HMI panel. This screen provides operators with intuitive controls (Start/Stop buttons) and real-time process visualization, including the pump's operational status, the current level in the supply tank, and a counter for successfully filled bottles.
• Automated Filling Process: The system executes a fully automated sequence: upon starting, the conveyor transports a bottle to the filling position. The PLC logic ensures the main tank has sufficient liquid before opening a valve for a predefined time to fill the bottle. Once filled, the bottle is moved along the conveyor, and the system is ready for the next one.
• Integrated PLC-HMI Simulation: The project leverages TIA Portal's powerful simulation tools to test and validate the entire system without physical hardware. The PLC logic is run on PLCSIM, and the HMI screen is run in the RT Simulator, demonstrating a seamless interaction between the controller and the operator interface.

This project effectively showcases the end-to-end development of a small-scale industrial automation system. It demonstrates strong proficiency in PLC programming with the Siemens S7-1200 platform, HMI screen design for operator interaction, and the use of integrated simulation for virtual commissioning and troubleshooting within the TIA Portal environment.

This project showcases the design and simulation of an automated industrial sorting system using Factory I/O and Control I/O. The primary objective is to sort pallets carrying boxes of different sizes onto two separate conveyor lines based on their height. The control logic is developed in Control I/O using a Function Block Diagram (FBD) approach, demonstrating a practical application of PLC-style programming in a virtual commissioning environment.

• 3D Industrial Simulation: Utilization of Factory I/O to create a realistic digital twin of a conveyor system, complete with sensors, actuators, and physical constraints.
• Function Block Diagram (FBD) Programming: The system's control logic is designed in Control I/O, using standard automation blocks such as logic gates (AND, NOT), latches (SR Flip-Flops), and edge detection triggers (RTRIG, FTRIG) to manage the operational sequence.
• Automated Sorting by Height: The core of the system is a central station where pallets are sorted. An array of optical sensors determines the height of the box on each pallet.
  • Tall boxes (detected by a "High sensor") are transferred to the right conveyor.
  • Short boxes (which do not trigger the "High sensor") are transferred to the left conveyor.
• Sensor and Actuator Integration: The system uses multiple diffuse sensors (Pallet sensor, Low sensor, High sensor) to detect the presence and size of items. This input is processed by the controller to operate the actuators, which include roller conveyors and a bi-directional chain transfer mechanism.
• Sequential Control Logic: The simulation demonstrates robust sequential control: pallets are moved into position, stopped, measured, transferred left or right based on the measurement, and then moved along the destination conveyor line.

This project effectively demonstrates skills in industrial automation, PLC-style programming, and virtual commissioning. It shows a complete workflow from defining an automation task to implementing and validating the control logic in a safe, simulated environment, which is a key practice in modern manufacturing and system integration.

This project demonstrates an industrial automation system that sorts pallets based on the height of the boxes they carry. The control logic is programmed in CODESYS, which then operates a virtual 3D factory environment simulated in Factory I/O.

• Software Used:
  • CODESYS: Used as the PLC (Programmable Logic Controller) development environment to create the control logic in Ladder Diagram (LD).
  • Factory I/O: Provides the 3D virtual factory scene ("Sorting by Height") with conveyors, sensors, and actuators for realistic simulation.
  • OPC Server: Facilitates the real-time communication between the CODESYS PLC and the Factory I/O simulation.
• Model: The simulation features a conveyor system with an entry line and two exit lines (left and right). A central chain transfer mechanism is used to move pallets between the lines. The system processes pallets carrying either low boxes or high boxes.
• Automation Logic & Control Flow: The core of the project is the PLC program which orchestrates the sorting process:
  • Process Start: The system is initiated via Start/Stop controls, managed by RS (Set-Reset) latches in the ladder logic.
  • Height Detection: As a pallet arrives at the sorting station, two vertically-stacked diffuse sensors (Low_sensor and High_sensor) determine the box size. A low box triggers only the bottom sensor, while a high box triggers both.
  • Sorting Decision: Based on the sensor inputs, the PLC logic decides whether to send the pallet to the left or right exit conveyor.
  • Material Handling: The PLC activates the chain transfer to lift the pallet, move it to the designated side, and then lower it onto the correct exit conveyor. The exit conveyors then transport the sorted pallets away.
• Visualization & Monitoring:
  • Real-time Simulation: The Factory I/O environment provides a dynamic, real-time visualization of the physical process, showing the pallets moving and being sorted according to the PLC's commands.
  • Live Logic Monitoring: The CODESYS interface is run alongside the simulation, allowing for live monitoring of the ladder logic. This shows the status of inputs (sensors) and outputs (actuators) as they change, which is essential for debugging and verification.

This project is a practical example of virtual commissioning, showcasing how PLC control logic can be developed, tested, and validated in a safe and realistic simulated environment before being deployed on physical hardware. It highlights the seamless integration between a powerful PLC IDE like CODESYS and an industrial simulation platform like Factory I/O.

This project demonstrates a PC-based control system featuring a custom-built HMI (Human-Machine Interface) developed in C# to supervise and control a virtual tank filling process. The C# application communicates directly with the Factory I/O simulation to create a complete, interactive control loop.

• Software Used:
  • Microsoft Visual Studio: The development environment for creating the custom HMI application using C# and the WPF framework for the user interface.
  • Factory I/O: Provides the 3D virtual process ("Filling Tank") with a tank, valves, and a level sensor.
  • Modbus TCP/IP: Serves as the communication protocol that enables real-time data exchange between the C# application and the Factory I/O simulation.
• Custom HMI Application: A bespoke supervisory control application was developed from scratch. Its main features include:
  • Control Panel: A comprehensive interface for system operation.
  • Dual-Mode Operation:
    • Manual Mode: Allows an operator to directly open and close the fill and discharge valves individually.
    • Automatic Mode: Executes a sequential, timed cycle of filling, pausing, and draining based on user-configurable time settings.
  • Real-time System Status:
    • A dynamic display shows the current tank level as a percentage.
    • Status indicators show whether the fill and discharge valves are active.
    • A timer tracks the progress of each phase in the automatic cycle.
• Control & Automation Logic: The entire control logic is implemented within the C# application.
  • The application reads the tank level sensor data from Factory I/O.
  • Based on user input from the HMI and the selected mode (Manual/Automatic), it sends commands to actuate the fill and discharge valves in Factory I/O.
  • The automatic cycle is managed by timers programmed directly in the C# code.

This project showcases a powerful approach to industrial automation by replacing a traditional PLC with a custom software application. It demonstrates the entire workflow of developing a PC-based SCADA/HMI system, integrating it with a virtual plant via a standard industrial protocol, and using it for both manual and automated process control.