Design and Development of a water fountain using PLC । পিএলসি ব্যবহার করে একটি জল ফোয়ারা নকশা এবং উন্নয়ন
ABSTRACT
In this paper, a Design and Development of a Water Fountain using PLC is discussed. Design
and Development of a Water Fountain using PLC, which is fully automatic system and it is
design based on Programmable Logic Controller. It has two-flow line, one is through the
mainline and the other one is the bypass line. As soon as the power is supplied to the system,
it is ready to run and start to flow the water through 4 nozzles according to the program in the
PLC for 10 second. Afterward one of them will stop flowing and the other three will continue
flowing for 5 second. Then again the second one will stop flowing and the other two will
continue flowing for 5 second. Then again the third one will stop flowing and the last one
will continue flowing for 5 second and then all 4 nozzles will stop flowing for 2 second. The
cycle will start flowing again and again and continue the same way. There are some colored
lightings for more beatification. LS master K120s PLC is used for the project. The program
is written in ladder diagram. There is some edit option through which it possible to change
program if needed on the basis of user demand. Water Fountain is used in natural
beautification for entertainment.
Design and Development of a Water Fountain using PLC, which is fully automatic system
and it is design based on Programmable Logic Controller. It has two-flow line, one is through
the mainline in figure: 02(4) and the other one is the bypass line, which is mentioned in the
figure: 02 (7). As soon as the power is supplied to the system, it is ready to run and start to
flow the water through 4 nozzles according to the program in the PLC for 10 second.
Afterward one of them will stop flowing and the other three will continue flowing for 5
second. Then again the second one will stop flowing and the other two will continue flowing
and the system will continue same way. And after finishing one cycle 4 nozzles will stop
flowing. The cycle will start flowing again and again. There are some colored lightings for
more beatification. LS master K120s PLC is used for the project. The program is written in
ladder diagram. There is some edit option through which it possible to change program if
needed on the basis of user demand. Water Fountain is used in natural beautification for
entertainment.
1.2 Objectives:
To Design a modern technology based water fountain
™ To design a portable fountain.
™ To provide a more beautification with colored lightings
™ To design a water fountain for beautification in interior decoration.
™ It provides a cool breeze during the operation.
1.3 The History of Water Fountains:
The history of water fountains dates back thousands of years. Ancient Greeks built water
fountain above springs that where thought have magical power. Water fountains have
included replica of the Greek gods and goddesses. Ancient Romans copied this Greek design
in the construction of Ancient Roman fountains.
Some of the most complicated fountains were built during the Renaissance (1500-1700) and
the most world famous fountains were constructed from 1600-1700.Many of the fountains
constructed in the US during 1800-1900 copied the classical designs. Artificial fountains
include electronics mechanisms to control the flow of water, lighting and sounds.
1.4 Construction Principles and Structural Components:
The construction principles of fountain technology arise from the desired objective. It always
involves putting water into motion in order to produce a beautiful, eye-catching water pattern.
To achieve this, adequate quantities of water must first be available. In the ideal case, a
natural water reservoir in the form of a pond or lake will be available, usually; however, a
water reservoir must be constructed artificially and be filled from public water supply. Basins
are mostly of Ms Sheet, but there are also ready made basins of considerable size made from
fiberglass or similar synthetics. Once the matter of the water reservoir is settled, there is the
question of the movement of the water and the water display The water movement can
consist of a duel, hardly perceptible, flow of water flowing water in the form of a stream, a
spring, a mult-jet fountain, a transparent water bell, a powerful high fountain, or a rushing
waterfall. Under the heading 'Typology" the basic variants are described in detail. If the
designer has decided on a certain water pattern and therefore on a certain nozzle or nozzle
combination, the selection of the "driving force" the fountains pump, then follows. The
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simplest solution is to use a submersible motor pump under in the basin. The most important
criteria for selecting the pump its power and efficiency - How much water cans it force-over?
What period at which height? - Its corrosion resistance and endurance characteristics, with
these three main elements - the water reservoir, the fountain attachment and pump - a fully
serviceable fountain installation can be provided. It is important with any fountain installation
that these three main elements have an appropriate and harmonious relationship to each other.
The size and form of the water pattern should be adapted to the shape and size of the basin.
The fountain attachment ultimately selected determines the necessary water and pressure
requirements. The pump selected results from the two requirements last mentioned. All other
components of a fountain installation should enhance its appearance, simplify its operation
and maintenance, and automate certain sequences.
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Material used : MS Sheet
Output : 4Line
Motor Input : 2Line
Bypass : 4Line
Solenoid : 8Ps
Thickness : 5 mm
Height : 5′ with
Glass
Glass : Length 3.10′
Height 2′
Ball Valve : 4Ps
Weight without water : 50 Kg
Weight with water : 80 Kg
Solenoid : 8ps
Motor : 2Ps
Pipe diameter : ½”
Solenoid diameter : ½”
1.6 Fountain Components
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1.7 (1) - Basin
Fountains and water displays, massive basins of MS sheet should only be considered after
due consultation with the fountain, the maximum achievable height of any water jet shall not
exceed the shortest distance of that jet's base from the nearest edge of the basin. The basin
depth or water depth shall be the minimum practical to reduce water usage and cleaning the
basin and for prevention of accidents. The required equipment will need to be accommodated
at an appropriate depth, preferably in a formed sump open. The anticipated equipment system
must be taken into account at the planning and design stages.
1.8 (2) - Fountain Pump
The fountain pump is the driving force at the heart of the fountain unit. The pump type must
be suited to the intended use (wet or dry mounting). The pumping capacity results from the
water and pressure consumption of the fountain attachment used, less the friction losses of
the pipe work and water distributor.
A pump is a device used to move fluids, such as liquids or slurries, or gases. A pump
displaces a volume by physical or mechanical action. One common misconception about
pumps is the thought that they create pressure. Pumps alone do not create pressure; they only
displace fluid, causing a flow. ..
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This fantastic Dual Power Cast Iron Electric Clean Water Pump has a 0.5 HP motor to pump
a large amount of water in no time! It has a peak water flow of 35L/min and a Delivery Head
of 35 meters with Suction from up to 9 Meters. This Water Pump is an ideal unit for
dependable continuous operation such as pool pumping, increasing the water pressure in the
pipe, garden sprinkling, irrigation, cleaning and garden applications etc. Compact design with
mountable feet, this water pump is economical, reliable, safe and easy to operate.
1.9 Features:
0.5HP Motor
Cast Iron
High Quality Mechanical Seal Equipment
High Head, Steady Flow
™ Low Power Consumption
Pump has Peripheral Impeller containing numerous Radial Blades on its Edge
1.11 (3) - Fountain and Nozzle Attachment
The fountain fitting models the water to create definite shapes and movements. Sculptures
and simple spouts are also included in this group.
2.1 (4) - Solenoid Valve
The solenoid valve is controlled by the electronic water-level monitoring device and in its
open state serves for refilling the fountain.
A solenoid valve is an electromechanical device used for controlling liquid or gas flow. The
solenoid valve is controlled by electrical current, which is run through a coil. When the coil is
energized, a magnetic field is created, causing a plunger inside the coil to move. Depending
on the design of the valve, the plunger will either open or close the valve. When electrical
current is removed from the coil, the valve will return to its de-energized state.
In direct-acting solenoid valves, the plunger directly opens and closes an orifice inside the
valve. In pilot-operated valves (also called the servo-type), the plunger opens and closes a
pilot orifice. The inlet line pressure, which is led through the pilot orifice, opens and closes
the valve seal.
The most common solenoid valve has two ports: an inlet port and an outlet port. Advanced
designs may have three or more ports. In case of a two-port valve the flow is switched on or
off; in case of a three-port valve, the outflow is switched between the two outlet ports.
Multiple solenoid valves can be placed together on a manifold.
Solenoid valves make automation of fluid and gas control possible. Solenoid valves are the
most frequently used control elements in fluidics. Their tasks are to shut off, release, dose,
distribute or mix fluids. They are found in many application areas. Solenoids offer fast and
safe switching, high reliability, long service life, good medium compatibility of the materials
used, low control power and compact design.
2.2 Different Parts of Solenoid Valve :
The illustration below depicts the basic components of a solenoid valve. The valve shown in
Fig: Parts of Solenoid Valve is a normally closed, directing-acting valve. This type of
solenoid valve has the most simple and easy to understand principle of operation.
2.3 Solenoid Valve Operation:
A solenoid valve ha two main parts: the solenoid and the valve. The solenoid converts
electrical energy into mechanical energy, which, in turn, opens or closes the valve
mechanically. A direct acting valve has only a small flow circuit, shown within section E of
the diagram of Fig: Solenoid Valve Operation (mentioned as pilot valve). This diaphragm
piloted valve multiplies this small flow by using it to control the flow through much larger
orifice.
Solenoid valves may use metal seals or rubber seals, and may also have electrical interfaces
to allow for easy control. A spring may be used to hold the valve opened or closed while the
valve is not activated.
Solenoid Valve Operation shows the design of a basic valve. At the top figure is the valve in
its closed state. The water under pressure enters at A. B is an elastic diaphragm and above it
is a weak spring pushing it down. The function of this spring is irrelevant for now, as the
valve would stay closed even without it. The diaphragm has a pinhole through its center,
which allows a very small amount of water to flow through it. This water fills the cavity C on
the other side of the diaphragm so that pressure is equal on both sides of the diaphragm.
While the pressure is the same on both sides of the diaphragm, the force is greater on the
upper side which forces the valve shut against the incoming pressure. In the figure, the
surface being acted upon is greater on the upper side, which results in greater force. On the
upper side the pressure is acting on the entire surface of the diaphragm while on the lower
side it is only acting on the incoming pipe. This result in the valve being securely shut to any
flow and, the greater the input pressure, the greater the shutting force will be.
In the previous configuration a pin, which is the armature of the solenoid E, and which is
pushed down by a spring, blocked the small conduit D. If the solenoid is activated by drawing
the pin upwards via magnetic force from the solenoid current, the water in chamber C will
flow through this conduit D to the output side of the valve. The pressure in chamber C will
drop and the incoming pressure will lift the diaphragm thus opening the main valve. Water
now flows directly from A to F.
When the solenoid is again deactivated and the conduit D is closed again, the spring needs
very little force to push the diaphragm down again and the main valve closes. In practice
there is often no separate spring, the elastomer diaphragm is moulded so that it functions as
its own spring, preferring to be in the closed shape.
From this explanation it can be seen that this type of valve relies on a differential of pressure
between input and output as the pressure at the input must always be greater than the pressure
at the output for it to work. Should the pressure at the output, for any reason, rise above that
of the input then the valve would open regardless of the state of the solenoid and pilot valve.
In some solenoid valves the solenoid acts directly on the main valve. Others use a small,
complete solenoid valve, known as a pilot, to actuate a larger valve. While the second type is
actually a solenoid valve combined with a pneumatically actuated valve, they are sold and
packaged as a single unit referred to as a solenoid valve. Piloted valves require much less
power to control, but they are noticeably slower. Piloted solenoids usually need full power at
all times to open and stay open, where a direct acting solenoid may only need full power for a
short period of time to open it, and only low power to hold it.
2.4 Technical Specifications of Solenoid Valve Used in the Project:
Name : Solenoid Valve
Origin Co. : Zejiang Leierda Pneumatic Liquid Pressure Co. Ltd
Model : 2W-025-08
Fluid applied : Water, Air. Oil,
Gas
Style : NC style
Adapter diameter : 1/2'
Working pressure : 0~5 kg/cm2
Max pressure : 10 kg/cm2
Operating temperature : -5~80° C
Body material : Brass
3.1 (5) - Suction Pipe:
The suction pipe serves the dry-mounted centrifugal pump for the suction of the water out of the
fountain basin. lt should be adequately dirnensioned in accordance with the volumetric delivery
of the pump. The flow speed in the suction pipe should not exceed 2 ft/sec.
3.2 (6) - Water Lights
By using water lights it is guaranteed that fountain installations are shown to good effect in the
evening and night-time hours also-often more effective than during the day. Additional effects
can be produced with color filters and color animation.
3.3 (7) – Bypass solenoid
The solenoid valve is controlled by the electronic water-level monitoring device and in its open
state serves for Bypass the fountain.
3.4 (8) - Drain Pipe
The drain pipe, combined with the floor drain and the drain valve, serves for carrying away the
basin water during the draining.
4.1 (9) - Electrical Control panel:
The electrical controls and switch gear is the switching and control centre of the fountain
installation. It contains all components necessary for electrical safety, protection of persons,
for equipment protection and for the automatic switching on and off of the pump and the
illumination.
4.2 PLC Panel Board:
4.3 Technical Specifications of the Panel Board
Material used : MS Sheet
Relay : 9 Ps
Breaker : 4 Ps
PLC : 1 Ps
Emergence : 1 Ps
Indicator Light : 4 Ps
Glass : 2*3In
On/Off Switch : 1 Ps
Total power : 950w
4.4 PLC Program:
4.5 Installation Environment:
1. Avoid installing the PLC at following locations where;
Temperature may experience ambient drops or rising.
(It should stay within 0ºC to 55ºC (32ºF ~ 131ºF))
- Condensation may occur due to abrupt temperature changes.
- Vibration and shock are directly transmitted to the PLC.
- The PLC is exposed to the direct rays of the sun.
- The PLC is exposed to corrosive or inflammable gas.
- The PLC is exposed to conductive powder.
2. Install the PLC at least 50mm away from a duct or other devices.
4.6 Features :
1) MASTER-K120S series is extremely compact, to fit a wide range of applications and have
following features.
(1) High speed processing of 0.1~0.9 s/step with an general purpose processor included.
(2) The main unit can perform many functions without using separate modules. Therefore, it
is possible to construct various
- Fast Processing Applications
- Pulse catch: Allows the main unit to read a pulse which has width as small as 10 ㎲.
- High speed counter (Economic): Support high-speed counting up to 100(10)kHz for 1
phase, 50(5)kHz for 2 phase.
- The input filter function help reduce the possibility of false input conditions from external
noise, such as signal
-Using RS-232C MASTER-K120S can connects with external devices, such as personal
computers or monitoring devices and communicate 1:N with MASTER-K120S system.
- Using built-in PID control function, PID control system can be constructed without using
separate PID module.
(3) Battery-less The user’s program can be saved permanently, because it is stored to
EEPROM.
(4) When program is edited during processing, it is stored to EEPROM automatically
(6) Various special modules that enlarge the range of application of the PLC
(7) It can easily do On/Off of the system, using RUN/STOP switch.
(8) It can easily save the user program in EEPROM by simple manipulation in KGLWIN
without using external memory.
(9) Strong self-diagnostic functions
It can detect the cause of errors with more detailed error codes.
(10) It can prevent unintentional reading and writing, using password.
(11) Debugging function (Standard type)
On-line debugging is available when the PLC Operation mode is set to debug mode.
Executed by one command.
Executed by break-point settings.
Executed by the condition of the device
Executed by the specified scan time.
(12) Various program execution function
External and internal interrupt program as well as scan program can be executed by setting
the execution condition.
Therefore, user can set variously program execution mode.
4.7 Source Input:
Current flows from the PLC input terminal to the switch after an input signal turns on.
4.8 Source Output:
Current flows from the output terminal to the load and the PLC output turn on.
4.9 Product Functional Block
Product function block for the K120S series is as follows.
4.10 CPU:
Signal processing function
- Operating system function
- Application program storage / memory function
- Data storage / memory function
- Application program execution function
Input:
The input signals obtained from the machine/process to appropriate signal levels for
processing.
Output:
The output signals obtained from the signal processing function to appropriate signal levels to
drive actuators and/or displays.
Power Supply:
Provides for conversion and isolation of the PLC system power from the main supply
Communication Interface:
Provides the data exchange with other systems or PADT, such as KGLWIN, personal
Computers
Main Unit – Standard type:
Models: K7M-DR20U
I/O Point & Power Supply: 12 DC inputs (24VDC), 8 relay outputs, 85~264 VAC.
Built-in Function:
Program capacity: 10 k steps
Max.
Expansion: 3 modules
High-speed counter:
- 1
Phase: 100 kHz 1channel, 20 kHz 2channel.
- 2 Phase: 50 kHz 1channel, 10 kHz 1channel.
Pulse catch: pulse width 10 ㎲ 2 points, 50 ㎲ 6 points,
External interrupt: 10 ㎲ 2 points, 50 ㎲ 6 points
Input filter: 0 ~ 1000ms (can be designated with groups)
PID control function
RS-232C communication
4.11 Name of Parts: Main Unitঃ
2- I/O LED- Indicates operating status of I/O
3- Built-in RS-485 connector
(Except K7M-DR10/14UE)- 2-pin connector for built-in RS-485 communications.
4- Key switch for mode creation
.(Except economic type)
- Designates main unit’s operation mode
RUN : Run program operation
STOP: Stop program operation
PAU / REM: usage of each module are as follows:
Stopping program operation
- REMOTE: designates remote driving
5- Dip-switch for Cnet I/F6- RS-232C connector- 9-pin D
IN connector to connect with external devices
like KGLWIN
7- Private hook DIN rail- Private part hook for DIN rail.
4.12 Points PLC:
4.13 Power Supply Specifications PLC
Input- Rated voltage 85 ~ 264 VAC
Rated frequency 50 / 60 Hz (47 ~ 63 Hz)
Rated current 0.5A (110VAC)/0.25A (220VAC)
Inrush current Up to 30A
Efficiency 65% min. (rated input/maximum load)
Output- Output voltage DC 24V (-)
Output current 0.2A
Power supply status indication PWR LED On when power supply is normal.
4.14 Electrical connection control board:
5.1 Relay:
A relay is an electrically operated switch. Current flowing through the coil of the relay
creates a magnetic field which attracts a lever and changes the switch contacts. The coil
current can be on or off so relays have two switch positions and most have double throw
(changeover).
Like all relays, the SSR requires relatively low control circuit energy to switch the output
state from OFF to ON or vice versa. Since this control energy is very much lower than the
output power controllable by the relay at full load, power gain in an SSR is substantial –
frequently much higher than in an electromagnetic relay of comparable output rating.
The relay's switch connections are usually labelled COM, NC and NO:
COM = Common, always connect to this; it is the moving part of the switch.
NC = Normally Closed, COM is connected to this when the relay coil is off.
NO = Normally Open, COM is connected to this when the relay coil is on.
5.2 Choosing a relay:
Physical size and pin arrangement
We are choosing a relay for an existing PCB you will need to ensure that its dimensions and
pin arrangement are suitable. You should find this information in the supplier's catalogue.
Coilvoltage
The relay's coil voltage rating and resistance must suit the circuit powering the relay coil.
Many relays have a coil rated for a 12V supply but 5V and 24V relays are also readily
available. Some relays operate perfectly well with a supply voltage which is a little lower
than their rated value.
Coil resistance
The circuit must be able to supply the current required by the relay coil. You can use Ohm's
law to calculate the current:
Relay coil current = supply voltage/coil resistance
For example: A 12V supply relay with a coil resistance of 400 passes a current of 30mA.
This is OK for a 555 timer IC (maximum output current 200mA), but it is too much for most
ICs and they will require a transistor to amplify the current.
Switch ratings (voltage and current):
The relay's switch contacts must be suitable for the circuit they are to control. You will need
to check the voltage and current ratings. Note that the voltage rating is usually higher for AC,
for example: "5A at 24V DC or 125V AC".
Switch contact arrangement (SPDT, DPDT etc)
Most relays are SPDT or DPDT which are often described as "single pole changeover"
(SPCO) or "double pole changeover" (DPCO).
5.5 Technical Specifications of Relay Used for the Project:
Name : Single Phase Relay
Place of Origin : China
Brand Name : Omron
Model No : MY4IN
Usages : General purpose
Size : Miniature
Protect
Feature : Sealed
Control Current : 5 A max
Make-on
Voltage : 24VDC
Load V
oltage : 280 VAC
Load
Current : 30 A
Operating
Frequency on Load : 50/60 Hz
ON-OFF time : ≤5ms
Installation : Relay Socket
5.6 Advantages of relays: •
Relays can switch AC and DC, transistors
• Can only switch DC.
• Relays can switch higher voltages than standard transistors.
• Relays are often a better choice for switching large currents (> 5A).
• Relays can switch many contacts at once.
5.7 Disadvantages of relays:
• Relays are bulkier than transistors for switching small currents.
• Relays cannot switch rapidly (except reed relays), transistors can switch many times
per second.
• Relays use more power due to the current flowing through their coil.
• Relays require more current than many ICs can provide, so a low power transistor
may be needed to switch the current for the relay's coil.
5.8 Circuit breaker:
Switching device designed to protect an electric circuit from overloads such as excessive
current flows and voltage failures. It has the same action as a fuse, and many houses now
have a circuit breaker between the incoming mains supply and the domestic circuits. Circuit
breakers usually work by means of magnetic-type relays or solenoids. Those at electricitygenerating stations have to be specially designed to prevent dangerous arcing (the release of
luminous discharge) when the high-voltage supply is switched off. They may use an air blast
or oil immersion to quench the arc.When a current exceeds a fixed limit as it flows through
the magnetic coil of a circuit breaker, a triggering mechanism is released, pulling the contacts
apart and opening the circuit, thus preventing any more current flowing. Circuit breakers
have many advantages; for example, they are fast acting, can be adjusted to operate at
different current values, and can be easily reset.
5.9 Emergency switch:
In factories and the like where industrial machinery is installed, in order to ensure the safety
of an operator in cases such as where a fault occurs during operation of machinery, an
emergency stop switch for emergency stop of the machinery is necessarily provided. A
machine is typically powered by an electrical power source and typically has an on/off switch
for use during normal operating conditions. For safety reasons, a machine will usually also
include an emergency stop switch for terminating electrical power to the machine in an
emergency situation. The emergency switch is activated under circumstances demanding an
immediate cessation of operation of the machine. Most of the conventional exercise apparatus
driven by electric motor include an emergency stop switch in the circuit controller for an
immediate cutoff of the power supply to stop the motor, thereby ensuring the safety of the
operator. An emergency stop safety switch as commonly used in machinery or exercise
equipment utilizes either a push-button or pull configuration.
5.10 (10) – Water chamber :
The chamber is to be water mounted a separate chamber not necessary. Since output water
are usually used, installation below the basin and chamber water level is advisable, it is
therefore often necessary to build the basin chamber into the base, Cellars if suitable, can also
be used to house the fountain equipment.
6.1 Comparative Analysis:
6.2 DISCUSSION:
Design and Development of a water fountain using PLC is the project for beautification. PLC is
used as automation tool to control the operation of solenoid valves and motors. In this project
Relay is used to interface the peripherals between Solenoid Valve and motor, those are operated
by high power AC source. The PLC, where both inputs and outputs pulse is low power DC
signal. The operation of this PLC based ‘Water fountain’ is reliable, accurate, safe and cost
effective which enhance the customers to establish such plant.
6.3 CONCLUSION:
If water fountain can promulgate or make known to the public, then it can be a symbol of
beautification.
6.4 REFERENCES:
1. B.L. Theraja, A.K. Theraja, A textbook of Electrical Technology, Volume-II, 23rd
Edition, Published by S. Chand & Company Ltd, 2006.
2. Frank D.Petruzeella, Programmable Logic Controllers, Second Edition, 1998
3. Muhammad H. Rashid, Power Electronics, Circuits, Devices and Applications, 3rd
Edition, Published by Prentice-Hall of India Private Limited, 2007.
4. R.S. Khurmi, A textbook of Engineering Mechanics, 19th Edition, Published by S. Chand
& Company Ltd, 1994.
5. W. Bolton, Mechatronics, Electronic Control System in Mechanical and Electrical
Engineering, 3rd Edition, Published by Pearson Education, 2006.
6. www.Program-PLC.blogspot.com
7. www.gavazzionlion .com/pdf/K120suerManual.pdf
8. www.royalfountains.com/fountain-design/fountain-design-principles.htm
9. www.interfountain.com
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