Master of Engineering Technology in Industrial Automation Assessment

System Requirements

1. Start the pump when the water level is low (below the lower sensor).
2. Stop the pump when the water level reaches the upper sensor.
3. Count pump operating cycles (start–stop events).
4. Display a maintenance warning after 100 cycles (for demonstration, use 5 cycles).
5. Lock out the pump after an additional 20 cycles (for demo, use 3 cycles).
6. Allow a maintenance reset only after the warning has been triggered.
7. Indicate system status using Pilot lights: Green = Pump ON, Yellow = Maintenance Due, Red = System Locked (Flashing Red light).
8. Be tamper-proof, ensuring the reset can only occur after the maintenance warning has appeared.

Hardware Requirements (for demonstration)

• Siemens S7-300 PLC
• Two push buttons (simulate upper and lower level sensors)
• Three Pilot lights(Green, Yellow, Red)
• One relay and a small DC motor (simulate pump)
• Jumper wires and power supply
• Any other components you deem necessary

Objectives

• Design a PLC program to control the automated tank level control and maintenance alert system.

Tasks:

You are required to:

1. Develop the System Wiring diagram
2. Develop a System Algorithm:
   • Create an algorithm outlining states and transitions based on inputs and outputs.
3. Design the PLC Program: Design and develop the automated tank level control and maintenance alert system using appropriate techniques, resources, and tools. o Write a ladder logic program using PLC software (Siemens TIA Portal).
   • Add comments in the code for clarity.
4. Safety Considerations: Include, amongst other things, an accessible emergency stop button to halt operations.
5. Report: Prepare a technical report following the structure in Appendix A, including:
   • Description of the proposed solution. o Wiring diagram for the system.
   • Software used (e.g., PLC programming software, simulation tools). o Commented PLC program. o       Limitations, assumptions, and constraints.
   • Safety precautions adhered to.
6. Presentation: Present the designed system and report under formal examination conditions for assessment.         

Appendix A: Report Structure

Your report should have the following components:

a. Title page

o This page gives:

• the title of the report
• the authors’ names and student IDs
• the unit name and code, the department, and the university ▪ the date of submission.

b. Declaration page – The declaration statement should be signed by the student and dated. It should be placed at the beginning of the report, after the title page before the summary.

c. Summary page

In ≈ 150 – 200 words, provide a concise overview of the entire project.Describe:

• The problem being addressed
• The main objectives of the system
• The tools and techniques used
• Key results or outcomes of testing
• A brief statement on how the work demonstrates GA5 (use of engineering methods, skills, and IT tools) o The Summary does NOT:
• provide background information on the topic
• explain the motivation for the project
• refer to figures, tables or references contained in the report.

d. Table of Contents page

o List of sections, figures, and tables with corresponding page numbers automatically generated.

e. Introduction

o Provide a brief overview of the project and its purpose. Describe the context of the automation problem, the motivation for solving it, and the expected learning outcomes. Link your project objectives to Graduate Attribute 5 (GA5).

f. Problem Definition

o Clearly define the problem the system addresses. Explain the operational challenges (e.g., manual pump control, overfilling, maintenance delays). State the design goals and key performance criteria such as simplicity, safety, and cost-effectiveness.

g. System Description

o Provide an overview of the proposed solution. Describe how the system operates and how each part contributes to solving the problem. Identify all inputs, outputs, and control logic used.

o Include your block diagram here.

h. System Design and Implementation

o Hardware Design

• List and describe all components used. Include a wiring diagram and explain the configuration and connection of components.

o Software Design

• Describe the software tools used. Provide a flowchart, state diagram, or pseudocode that explains your program logic. Include your final program listing with comments.

o System Operation

• Explain how the system operates under normal and maintenance conditions. Describe how sensors trigger control actions and how maintenance cycles and lockout features are implemented.

i. Testing and Results o Describe the testing process used to verify your system’s functionality.

Present test conditions, procedures, and outcomes in a table or list format. Include photos or screenshots showing the system in operation.

j. Discussion

• • Discuss the system performance, accuracy, and limitations observed. Reflect on design decisions, strengths, and weaknesses. Explain how the selected tools and techniques helped solve the problem effectively.

k. Limitations, Assumptions, and Constraints o Identify any simplifications or assumptions made in the design. Mention hardware or software constraints that affected your results. Consider safety, environmental, or cost limitations.

l. Conclusions and Recommendations o Summarise your project achievements and how they meet the system requirements. Highlight what you learned about using engineering tools and information technology to solve a well-defined automation problem.

m. References o List all references used in IEEE format, including datasheets, software documentation, and online resources.

n. Appendices (Optional) o Appendices contain material that is too detailed to include in the main report, such as long mathematical derivations or calculations, detailed technical drawings, code or tables of raw data. The content should be summarised and referred to at the appropriate point in the body of the report.

The conventions for appendices are as follows:

• each appendix must be labelled with a number (or letter) and title
• the appendix numbers and titles must be listed on the Contents page under the heading Appendices (if more than one) or Appendix (if only one)
• each appendix must be referred to by number (or letter) at the relevant point in the text.

Include supporting materials such as:

• Full program listing
• Additional wiring diagrams
• Simulation screenshots or test data
• Any other relevant documentation

o. Rubric for GA 5

Answer

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