KOCAELI UNIVERSITY

ENGINEERING FACULTY
MECHATRONIC E NGINEERING
PLC
END of TERM PROJECT
SPRING 30.04.2021

AIM:
PLC BASED ELEVATOR CONTROL SYSTEM.

PREPARED BY:
LEONEL AKANJI AKANJI 170223087
 CONTENTS
1. INTRODUCTION: --------------------------------------------------------------------------------1
2. LITERATURE REVIEW: ------------------------------------------------------------------------1
3. BLOCK DIAGRAM AND FUNCTIONALITY: ---------------------------------------------2
3.1 PLC Controller: ------------------------------------------------------------------------------2
3.2 Elevator Cabin: ------------------------------------------------------------------------------2
3.3 Power Supply: -------------------------------------------------------------------------------2
3.4 Motor: -----------------------------------------------------------------------------------------3
3.5 Motor Driver: --------------------------------------------------------------------------------3
3.6 Sensors: ---------------------------------------------------------------------------------------3
3.7 Buttons: ---------------------------------------------------------------------------------------4
3.8 7 Segment Display: -------------------------------------------------------------------------4
3.9 Indicator: -------------------------------------------------------------------------------------4
4. SOFTWARE IMPLEMENTATION: ---------------------------------------------------------4
4.1 TON: ------------------------------------------------------------------------------------------5
4.2 02-CMD Outputs:----------------------------------------------------------------------------5
4.3 01-GRAFCET: ------------------------------------------------------------------------------8
4.4 Startup: ---------------------------------------------------------------------------------------11
4.5 Main: -----------------------------------------------------------------------------------------11
4.6 Tags Variable: ------------------------------------------------------------------------------12
4.7 Method: --------------------------------------------------------------------------------------13
5. PROBLEMS AND SUGGESTED SOLUTIONS: ------------------------------------------13
5.1 Danger When Reinitializing The Actual Values For TON: --------------------------13
5.2 TIA Portal License Error: -----------------------------------------------------------------13
6. CONCLUSION: ----------------------------------------------------------------------------------14
7. REFERENCES: ----------------------------------------------------------------------------------14
1. INTRODUCTION:

With the aim to demonstrate the knowledge learned from the Programmable Logic
Controller (PLC) lesson, a three-floor simplex PLC based Elevator Controller (PLC-EC)
was designed. With this design, the algorithms and functionality of PLC were
demonstrated by simulation in TIA portal software. This demonstration shows how
elevators ease the work of human being and keep them in comfort zone. Elevator control
system is needed to control all the functions of the elevator. It is the one which guides
the elevator car, which actually carries the passengers between the different floors; it
also controls the opening and closing of doors at different floor, and the safety switches
are also controlled by the elevator control system. Preliminarily, traditional elevator
control systems work on the relay logic. Some of the drawbacks of the traditional system
are the control system have high failure rate that were mainly due to numerous contacts,
complexity of wiring circuit. In addition, electrical contacts were easy to burn out, which
could result in poor contact [1].

A better use of PLC can be made in the designing of the elevator control system. This
control is based on the input that is received from the operator as well as from the
sensors at every floor. Because of the useful effect of PLC, elevator systems are getting
better, faster, stronger and better-quality elevators are produced as more importance is
given to the design of an elevator control system.

2. LITERATURE REVIEW:
Modern technology advancement plays a vital role in the society through the creation of
amazing resources and tools one of which is an elevator for vertical transportation.
Elevator is an important transport medium in multi-storage building. Hence an elevator
becomes an important medium of vertical transportation. There are several advantages of
an elevator in the modern world. Hence more importance is given to the design of an
elevator control system, which is easy for the maintenance and to perform an efficient
function. Preliminarily, traditional elevator control systems work on the relay logic.
More number of connections of relay logic are found in traditional elevator system.
Hence it is difficult to debug failures in the system and also it is highly feasible job to
facilitate alternate connections to the fault tolerant systems in the relay logic, where as in
PLC based system, it is easy to debug the failures in the system as it contains the simple
logics and easy maintenance. The main objective of this paper is to replace the
traditional relay logic elevator control system with the modern PLC based elevator
control system.

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3. BLOCK DIAGRAM AND FUNCTIONALITY:

Block diagram for PLC based elevator control system is as shown in figure below [2].

Figure 1: Block Diagram of an Elevator

3.1 PLC Controller:

A PLC is user friendly microprocessor based specialized computer that carries out
control function of many types and levels of complexity. PLC controller is main
element in this system which controls elevator functions. PLC receives input signal
from operator or various sensors used at different floor for performing many
functions. PLC controller produces control signals via output module which controls
the motor operation and feedback is given to PLC controller.

3.2 Elevator Cabin:

Elevator cabin is nothing but elevator car which carries peoples as well as goods in
upward and downward direction.
No. of switches and sensors are connected in an elevator car. According to
conditions present in car respective sensors
are operate automatically. Lighting and cooling arrangement is also provided in
elevator cabin.

3.3 Power Supply:

Power supply is given to PLC controller as well as motor drive circuit. The power
available in most plants is120 or 240 volts AC at 50 HZ. Most PLC operates on
+12volts and -12volts DC. Therefore, the PLC CPU must contain circuitry to convert
230 volts AC input to the required 5 volts DC value.

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3.4 Motor:
A motor is an electrical machine which converts an electrical energy in mechanical
energy. The elevator motor is responsible for moving an elevator car up and down
between floors. Elevator system uses a roped mechanism. The elevator engine is
connected to a pulley with ropes are looped around. The controller interacts with the
elevator engine by sending it a signal that specifies at which speed and in what
direction the engine should be going in. A stop signal is simply constructed by
setting the speed parameter of the signal to zero.

3.5 Motor Driver:

Motor driver is used to control the motor in forward and reverse direction. There are
four switching elements are used. The name H Bridge is derived from actual shape
of switching circuit which controls the motion of motor [4].

Figure 2: Motor Driver

Table I. Truth Table

High Left High Right Low Left Low Right Description
On Off Off On Motor runs
clockwise
Off On On Off Motor runs
anticlockwise
On On On On Motor stops or
decelerates
Off Off Off Off Motor stops or
decelerates.

3.6 Sensors:
A sensor is a device which converts a physical quantity into a signal used by an
observer or an instrument. A sensor's sensitivity indicates how much the sensor's
output changes, when the measured quantity changes. Many sensors are mounted on

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 different floors for performing various functions. An Infrared sensor is used as
Obstacle detector, a Load Cell as transducer to converts force which is to be
measured into an electrical signal and an oxygen sensor (or lambda sensor) as an
electronic device which measures the proportion of oxygen (O2) in the gas or liquid
being analysed and used in elevator application for protecting people during
emergency situation.

3.7 Buttons:
Push buttons are connected to PLC input module. A push button limit switch is used
as its automatically deenergises on release.

Figure 3: Push Button Switch

3.8 7 Segment Display:

In an elevator 7 segment display is used for floor and direction indication.

3.9 Indicator:
Indicator is connected at output module of PLC. It indicates direction of car which
may be upward or downward.

4 SOFTWARE IMPLEMENTATION:

The project software was divided in three main parts made from a ladder logic diagram
consisting of instructional contact components such as the normally closed contact,
normally open contact, ladder branches with the Generate On-delay timer (TON) as the
key control contact instruction.

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4.1 TON:

Figure 4: Delay Timer

The following table shows how the instruction works using specific operand values:

Table 3: Timer Operand and Value

Parameter Operand Value
IN Tag_Start Signal transition "0" => "1"
PT Tag_PresetTime T#10s
Q Tag_Status FALSE; after 10 s => TRUE
ET Tag_ElapsedTime from T#0s => T#10s

When the signal state of the "Tag_Start" operand changes from "0" to "1", the time
programmed for the PT parameter is started. When the time duration expires, the
"Tag_Status" operand is set to the signal state "1". The Tag_Status operand remains
set to "1" as long as the Tag_Start operand has signal state "1". The current time
value is stored in the "Tag_ElapsedTime" operand. When the signal state at the
operand "Tag_Start" changes from "1" to "0", the "Tag_Status" operand is reset.

4.2 02-CMD Outputs:

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4.3 01-GRAFCET:

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4.4 Startup:

4.5 Main:

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4.6 Tags variables:
Table 4: Tag Variables And Description

Name Datatype Description

"GRAF_STEPS".X0 Bool Master Start-Stop
"GRAF_STEPS".X1 Bool STEP1 : close door
"GRAF_STEPS".X2 Bool STEP2 : down elevator
"GRAF_STEPS".X3 Bool STEP3 : open door
"GRAF_STEPS".X4 Bool STEP4 : close door
"GRAF_STEPS".X5 Bool STEP5 : down elevator
"GRAF_STEPS".X6 Bool STEP6 : up elevator
"GRAF_STEPS".X7 Bool STEP7 : close door
"GRAF_STEPS".X8 Bool STEP8 : up elevator
"Inputs_images".P1 Bool Cabinet in Floor1
"Inputs_images".P2 Bool Cabinet in Floor2
"Inputs_images".P3 Bool Cabinet in Floor3
"Inputs_images".a Bool Door is Open
"Inputs_images".b Bool Door is Closed
"Inputs_images".BP_Call_S1 Bool Lift Assigned to Go to Floor1
"Inputs_images".BP_Call_S2 Bool Lift Assigned to Go to Floor2
"Inputs_images".BP_Call_S3 Bool Lift Assigned to Go to Floor3
"Outputs_Images".CMD_UP Bool Upward Movement
"Outputs_Images".CMD_Down Bool Downward Movement
"Outputs_Images".CMD_Open Door Bool Lift Call through the open command
"Outputs_Images".CMD_Close Door Bool Lift Close Command (and moves to the assigned floor)

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 4.7 Method:

k1 = x1 & k2=x3

Figure 5: Block Diagram of an Elevator

5 PROBLEMS AND SUGGESTED SOLUTIONS:

5.1 Danger When Reinitializing The Actual Values For TON:

Reinitializing the actual values of an IEC timer while the time measurement is
running disrupts the function of the IEC timer. Changing the actual values can
result in inconsistencies between the program and the actual process. This can
cause serious damage to property and personal injury. Loading the block with
reinitialization, loading snapshots as actual values, Controlling or forcing the
actual values, the "WRIT_DBL" instruction functions can cause the actual values
to be reinitialized.

Before the functions are executed, precautions such as making sure that the plant
is in a safe state before overwriting the actual values and making sure that the
IEC timer has expired before initializing its actual values should be taken.

5.2 TIA Portal License Error:

An HMI design was made but cannot be simulate (not also reported here)
because not all the tag variable could be migrated due to license limitation.

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6 CONCLUSION:

Previously Relays and IC boards was the only logic instruction used in controlling
elevator. But due to its inconvenience now it is replaced by PLC. PLC is easy for
controlling machines used in elevator. An elevator mentioned here is fully automated
using PLC. By using input signals from operator and sensors control operations are
performed such as moving forward and reverse, door opening and closing etc. According
to that signal PLC will make the drive motor and door motor to work correspondingly.
The proposed system has been implemented by using Ladder diagram programming as it
is easy to program the PLC.

7 REFERENCES:
[1] A M Anusha and Ashok V. Sutagundar, “Design of a PLC Based Elevator Control
System”, International Journal on Emerging Technologies (Special Issue on
NCRIET-2015) 6(2): 32-36(2015).
[2] Abdelkarim Ahmed Eltahir Ali, Zhang Jiang Min, “Design of Five Floors Elevator
with SCADA System Based onS7200 PLC”, International Journal of Science and
Research (IJSR) ISSN (Online): 2319-7064 Index Copernicus Value (2013): 6.14 |
Impact Factor (2015): 6.391 Volume 5 Issue 4, April 2016 www.ijsr.net.
[3] T.Y.Ladakhi et.al, “Application of PLC for Elevator Control System”, International
Symposium on Devices MEMS, Intelligent Systems & Communication (ISDMISC)
2011 Proceedings published by International Journal of Computer Applications
(IJCA) 4.
[4] Sandar Htay , Su Su Yi Mon, “Implementation Of PLC Based Elevator Control
System”, International Journal of Electronics and Computer Science Engineering-
ISSN- 2277-1956www.ijecse.org
[5] Yelpokonde Atikesh et.al., “Elevator Control System By Using PLC”, IJARIIE-
ISSN(O)-2395-4396 Vol-2 Issue-3 2016 www.ijariie.com.

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