DESIGN THE CAR PARK CONTROL USING GRAFCET

VIGNESH KUMAR S/O SUBRAMANIAM

This report is submitted in partial fulfillment of requirements for the Bachelor Degree of
Engineering ( Industrial Electronics )

KOLEJ UNIVERSITI TEKNIKAL KEBANGSAAN MALAYSIA

MEI 2006

ABSTRACT

The title of my project is design the car park control using Grafcet as programming tml. This project is chosen because it expases myself to few field of studies for example Grafcet and PLC. Furthermore this project also is very practically feasible to construct, practically applicable and useful and has the potential to be marketed in addition it is different from other existing similar in the market. The Grafcet is the design tool for the PLC was chosen since it gives more structured appraach rather than conventional way. %is project use the PLC to control the parking area. This simple car park control system allows a certain number of cars parking space. Every time a car comes in, the PLC will add one and subtract one when a car goes out. When a determined number of cars are registered, the car park full sign will be lighted to inform oncoming vehicles not to enter. Basically this system allows a car when there is a space in the car park and show sign (light) to inform when the car park is full.

The finai product of this project is a hlly functional hardware that achieves the initial objectives of this project and at the same time illustrates the practical feasibility of our idea. However since the main objectives is only to illustrate the practical feasibility of our idea, therefore the specification and quality of certain components have been c~mpromisedto reduce the project cost. Therefore in real life application, the specificatbns of certain mmpanents have to be changed for optimum and satisfactory performance.

CHAPTER I

f NTRQiEiUCTION

The aim of this final project is to design the car park control using the

and PLC to c o n b l the parking area. Basidly we mi&

k n c r ~ 7

what is

PLC. A PLC (Programmable Logic Controller) is a device that was invented to replace the necessary sequential relay circuits for machine control. The PLC works by looking at its inputs and depending upon their state, turning orv'off its outputs. l?x vser enters a program, usually via software, that gives the desired results. PLCs are used in many "real world" applications. If there is industry present, chances are good that there is a plc present. If you are involved in machining, packaging, material handling, automated assembly or countless other industries you are probably already using them. If you are not, you are wasting money and time. Almost any application that needs some type of electrical control has a need for a plc. For example, ld*sassume that when a switch turns on we want to turn a solenoid on for 5 seconds and then t m it off regardless of how long the switch is on for. We can do this with a simple external timer. But what if the process included 10 switches and solenoids? We would need 10 external timers. What if the process also needed to count how many times the switches individually
turned an? We need a lot of external counters,

As you can see the bigger the process the more of a need we have for a

PLC. We c a simply pragriLi t k PLC to caunt its inputs and turn the salenoids ~
on for the specified time. This site gives you enough information to be able to write programs far more complicated than the simple one above. We will take a look at what is considered to be the "top 20" plc instructions. It can be safely estimated that with a firm understding af these instructions one can solve mare than 80% of the. applications in existence. That's right, more than 80%! Of course we'll learn more than just these instructionsto help you solve almost ALL your potential plc applications.

1.1

Problem Statement

Among the analyzed problem is:

I ,not j

rieed manp-wer when the car park system can ft~nctionautomatically

because there is a sensor to detect when cars approach. Most of the car parking area do not have counter and full sign display to show the users whether there is a space for their vehicle can be parked or not. It is very difficult when there is no caunter display when a car comes in and out. So when a determined number of cars are registered, the car park full sign will be lighted to inform oncoming vehicles not to enter. Since some car parking system doesn't equipped with programmable signage to inform whetha the parking is full or not, the car users will waste their time and petrol consumptionto find a free parking lot. The data collection from the systems can be used for future development

Project Objectives

This project is consisted of two parts. Part I, the objectives of this work is to familiaize with the hardware itself, the b t i o n and the cantrolling elements. Since the PLC as the controller, the CX Programmer as the programming tool will also be learned in this part.

Part II, the objective is to write the programming using the GRAFCET as
a graphical t a d in order to develop the car park system. In f M k r , the objective is to show the GRAFCET can be used as a design tool that can helps the designers to come out with the structured, safety, working and readability control program.

The objective ifi producing such a project is to come up with something

that has never been ventured i n t ~ also that l o ~ k out f ~ technology, safety and s r and law abiding. This is where, I came up with an idea of create a display counter in the car park area to inform oncoming vehicles to enter or not to enter.

Every time a car comes in, the PLC will add one and subtract one when a car
goes out. When a determined number of cars are registered, the car park full sign will be libted. Basically this system allows a car when there is a space in the car park and show sign (light) to inform when the car park is full. The advantage of this system is convenient to people because it saves time, petrol, cuts down manpower and help to improve the techobgy in certain places. This system can also used in shopping complex, campus and private car park Internally, this project tests our knowledge in our area of specialty that is an electronic and electric theoretically as well as practically. In order to conduct our project, a lot of research and study has to be done on many things namely the counter, the working concept of a motor for parking bar, components and many more.

The project has also assigned because it makes us very important decision like time dividing among many things and the project, buiMs o w character where we have to be really hardworking and have the perseverance. Basically this is the objectives of the project that is going to be done in order to achieve a reasonable well one.

1.3

Project scopes of work

The scope of the work for this project is basically must familiarize with the PLC programming. Study about the PLC programming tool, "GRAFCET". Actually Grafcet is a flow chart that we plan how the system functions. In this project, we mainly concentrate on design using GRAFCET. Design a complete GRAFCET diagram of this module and transfer the designation of GRAFCET on to ladder diagram. Next, must familiarize with the equipments, components, and
the things that we need to be wed to create the car parking system.

Finally plan how to create or develop the model of the car parking system. I planned to use few equipments for the project such as sensors to detect the parking bar when car approach but then it is to expensive and costly.

h Therefore I planned to use micro switch as replacing the sensor for t e parking
bar in the project.

CHAPTER I1

LITERATURE STUDY / REWEW

2.0

Introduction
The cost of developing s o h a r e for the logic controller in the manufxtrrring world becoming increasing day by day. Furthermore, in designing the representation of the logic controller such as "PLC", many companies using a different languages. In the desire to improve the capability of this logic controller, these languages become more complex. This is in contradiction with the main goals of the PLC's, which is that he "PLC" is a very simple system because it is very important that "PLC" must be reliable. There obviously needs to be a consistent philosophy for development reusable code for manufacturing controller systems

In today's economic context, the design of these control applications is of

a great impact in terms of productivity and production costs. Because of these costs, of the complexity of the control system and the multiple

hzrrdware/sofiware combinations, the designer has to take the safety of this system into account. In this context, it is necessary to provide the designer with verification methods that ensure the safety and live ness of the control system. In deep, the verification methods will help the designer to troubleshoot the programs while the error occurs in the production. One way to ensure the safety of the PLC programs is by using "frameworlr;" or standard wbile programming process began.

Thus, the usage of GRAFCET is a very good tool for logic controller specification has been approved. It allows modeling of concurrency and synchronization. Above all, the input-output behavior is specified without doubt. When some parts of logic controller can be describe separately, one can use macro steps to simplifl the model. In addition, the comparison was made between State Table, Petri Net, RLL a d GRAFCET, and it make an evident that the GRAFCET applications was the easiest among all. The strength of the GRFACET is the graphical nature of the language makes GRAFCET easy to karn and use. The ability to test the different ideas quickly has been very useful in determining the final design. The GRAFCET helps the designer determine: modularization of the code, functions that can be performed in parallel, communication between parallel processes, and problems in conirol flow. The f&r extension of the GRAFCET usage which touches on

how these tools can be applied to the reduction of a model in a specific context such as for the model that has typically over fifty steps and transitions. The GRAFCET also has been successh~ in order to converting existing RLL programs into the form that considerably easier to understand and it's also helps to modify the programs. For the good solution, the GRAFCET can be implemented to avoid the damages and system failures during the plant operation, due to interactions between human operators and plant. This statement
was Wly supported &own that the GRAFCET language has a particular

characteristics that support supervision of external actions over a process. The results demonstrated shown that GRAFCET implementation over a PLC can avoid human errors and can indicate on a set of outputs, the parts and variables of the plant ha do not satisfy the interaction demand conditions. At the end, to make GRAFCET more efficient and applicable, it must introduce two different techniques to make proofs on the properties of this language

2.1

Historical Development

In 1975, the working group called "Logical Systems" fiom AFCET (Association Frmcaise de Cybemtique Economicyw et Tecnidque) create the standardization of a requirement representation of a logical automated system. This group trying to define a simple formalism, accepted by everyone and well-adapted for the representation of the sequential evolutions of a system understandable by designers
as well as by users

and providing potentially easiness for the implementation with

hardware andfor software solution. In December 1997, the Grafcet which means functional graph of a step- transition command was derived as a tool of state graph.
After Grafcet had been introduced in higher and technical education, it was

supported by the arrival of the first programming language. Allowing

implementation of Grafcet specification models on industrial logic controllers; it became an AFNOR standard in 1982known under the reference NF c03 190. Aware of the necessity to precise how to implement a Grafcet specification with hardware d o r software, a synthesis document on reccrmnded interpretation for the transformation from the Grafcet specification model to a specific realization. This though lead group to propose in 1987 in an AFCET. Synthesis document, a certain number of Grafcet extensions to meet users' expectation. So as to strengthen
the diffusion of Grafcet, and thanks to the efficient action of P a d BRARD (la

Telemecanique Electrique) Grafcet became an international standard in 1988 under name: "Sequential Function Chart" (SFC).

In 1989-1996, the study was carried out of the extension and moved towards a
strengthening of the Grafcet theoretical basis. As a matter of fact, the growing demand of Grafcet users regarding a good understanding of the complexity and the dynamic behaviors of the models, regarding the prove of characteristics for the development of safe operational system, or regarding the prospective use of the Grafcet model for M e r modeling tools, did not match the Grafcet definitions that were only textual.

In 1997 the p u p organized a presentation stand at EDUCATEC'97 from December 2nd to December 5th, 1997(CNIT -Paris La Defense) to mark the 20yh birthday of Grafcet. This event gave a complete review of the action led in education, industry, standardization, and research and to show the progress mate during the last 20 years. In June 1998 an invited session at IFAC INCOME'% drew attention to foreign laboratories which carry on with researches on Grafcet. The theoretical works on the Grafcet in model are increased by taking into account the characteristics of Grafcet in relation to the characteristics of the system which describe the behavior.

In this sense, the current orientations aim at better defining the properties of the frontier separating Grafcet from its environment (interactions by input- outputs, topology of these interactions exploiting the definition of both temporal scales, receptivities, actions, events, the taking into account of the semantics of the modelized system as a guide for the elaboration of Grafcet. I the future ,the Grafcet g o u p will certainly imagine other actions of the same k i d in order to enable Grafcet to remind a model with a rich past and a promising future.

The Guts f nside

Figure 2.0: PLC CPU

~ ~

The PLC mainly consists of a CPU, memory areas, and appropriate circuits to receive inputhutput data as shown in Figure 2.0. We can actually ansider t e h PLC to be a box full of hundreds or thousands of separate relays, counters, timers and data storage locations. Do these counters, timers, etc. really exist? No, they don't "physically" exist but rather they are simulated and can be considered software counters, timers, etc. These internal relays are simulated through bit locations in registers. What does each part do?

INPUT RELAYS-(contacts) these are connected to the outside world. They

physically exist and receive signals fiom switches, sensors, etc. Typically they

arenot relays but rather they are transistors.

INTERNAL UTILITY RELAYS-(contacts) these do not receive signals from the outside world nor do they physically exist. They are simulated relays and are what enables a PLC to eliminate external relays. There are also some special relays that are dedicated to performing only one task. Some are always on while some are always off. Some are on only once during power-on and are typically

used far initializing data that was stored.

COUNTERS-These again do not physically exist. They are simulated counters and

d x y can be p r a g r d to count pulses. Typically these counters can count up,

down or both up and down. Since they are simulated they are limited in their counting speed. Some manufacturers also include high-speed counters that are hardware based. We can think of these as physically existing. Most times these munters can count up, dawn or up and dawn.

TIMERS-These also do

physically exist. They come in many varieties and

increments. The most common type is an on-delay type. Others include off-delay and both retentive and non-retentive types. Increments vary fiom lms through

1 s.
OUTPUT RELAYS-(coils) these are connected to the outside world. They

physically exist and send oxdoff signals to salenoids, lights, etc. They can be
transistors, relays, or triacs depending upon the model chosen.

DATA STORAGE-Typicallythere are registers assigned to simply store data. They

are usually used as temporary storage for math or data manipulation. They can also typically be used to store data when power is removed from the PLC. Upon purer-up they will still have the same contents as before pawer was removed. Very convenient and necessary

PLC Operation
A FLC works by continually scanning a program. We can think of this scan cycle
as consisting af 3 important steps. There are typically more than 3 but we can focus an

the important parts and not worry about the others. Typically the others are checking the system and updating the current internal counter and timer values.

EXECUTE P H O G W M

Figure 2.1

Scan Cycle

Step I-CHECK INPUT STATUS-First the FLC takes a look at each input to determine if it is an or off. In other words, is the sensor connected to the first input on? Haw a b u t the second input? How about the third. It records this data into its memory to be used during the next step.

Step ZEXECUTE PROGRAM-Next the PLC executes your program one instruction at a time. Maybe your program said that if t!x first input was an then it &auld turn an the first output. Since it already knows which inputs are onloff fiom the previous step it will be able to decide whether the first output should be turned on based on the state of the first input. It will store the execution results for use later during the next step.

Step 3-UPDATE OUTPUT STATUS-Finally the PLC updates the status of the outputs. It updates the outputs based on which inputs were an during the first step and the results of executing your program during the second step. Based on the example in step 2 it would now turn on the first output because the first input was on and your program said to turn on the first output when this condition is true.

After the third step the PLC goes back to step one and repeats the steps continuously.
One scan time is defined as the time it takes to execute the 3 steps listed above.

CHAPTER III

METHODOLOGY

Referring to Figure 3.0, there are few stages that will be involved in order to work out the aimed objectives in this project. The figure was intended to f a t w e the entire project process. Initially, the first stage highlighting the preparation and familiarization level. The second stage is regarding the study and familiarization of the GRAFCET as

the design tool to represent the logic controller. Since the available references using
higher technical standard jargon, the author tried to produce a guideline that can helps the lecturers and students in future usage, aimed to represent the GRAFCET in a simple approach. Some experimental workings were developed in order to get more understanding how the GRAFCET itself.

This importance part in this project is to develop the programming design the car
park system using the GRAFCET as a too1 design. The CX-Programmer, the

programming tool for OMRON PLC is applied to create the progams of the car park system.

PRafECT METHODOLOGY

Create ideas accodmg to the need ofthe p q n s e d pmject

Design f malpmject h

Search for informatian

fwpJwtfrwnbaaksaf - l i b r a r y a d also in
'

Test runthe project

Disclss with the pmject supervisor h u l ideas and =search

Simulate the circuit

Figure 3.0: Methodology Fiow Chart

3.1

Introduction
The producers and methods that been used to achieve the project is plan how to design a smart car parking system. So to gain sane knowledge I have done a survey throughout Malacca and Johor Bahru ( Southern zone ) to find out what type of car parking system have been using. So far, I have realized that only place using the smart car park system that i plan to design for my f i d year project is at KLIA ( K d a Lumprrr International Airport). Since KLIA have implemented this car park design I take an initiative to go and have a look on the car park system. I have snap few photos around the
car parking area at KLIA. Below are the pictures:

Figure 3.1: KLIA Car Parking Areas

Figure 3.2: Displays for Vacant Bays at KLIA

Figure 3.3: Display and Counter at KLIA

3.2 Research and Analysis on car parking system at Malacca.

From the research and observation that I have done in few places at Malacca shows that there is no any car park system with car in and out counter display

and full sign display. Below shows few figure at car parking area in Malacca.

Figure 3.4: Malacca Central car parking system.

Figure 3.5: Malacca Central car parking system.

Figure 3.6: Jaya Jusco car parking system,

Figure 3.7: Multimedia University BBU apartments (hostel)

3.3 Major P r s and Materials that need for my Project at

DESCRiFTtON NO. COMPONENTS

Power Window Motor f 12V )

Battery (Lead Acid) ( 12V )

m m switetl
Relays ( 2 way )
a) Power window motor (Mitsubishi)

Figure 3.8: P m e r wiadm metop

Figttre 3.%12 V w i d o w mmtor

These are some example of power window motor shown in Figure 3.8 and 3.9 that I want to use for my hardware project. The purpose of the power window motor for my project is to modify the motor and it act as the parking bar (open and close). There is

a critical work to design the motor and make the motor to function as parking bar. The

DC power window motor is 12 Volt and smaller in size compare to other DC motor such
as w i d o w viper motor. Power window motor is inexpensive and not heavy compare to

window viper motor.

1 have done a survey about the price of power window motor in Malacca. At last
I b u g h t the power window motor at the second-hand car items whereby the price is
much cheaper rather then buy a new one. The price of power window motor is RM 37.00 per unit.

Figure 3.1OA :Limit Switch

Figure 3.1OB :Limit Switch

These are micro switches shown in Figure 3.10 that I want to use for my hardware project. The pupase of this micro switch is to control and function perfectly when a car approaches at the parking bar. It will make sure the parking bar open in 90" and close back in proper. In the beginning I planned to use Metal Detector sensor as the micro switch but it

is to expensive. Finally after discussed, I plan to use micro switch as replacement f ~the r
Metal Detector sensor because it is cheap and small in size makes me easier to design the hardware project.

Figure 3.1 1:Relay

These are a Refay (2 ways) that 1 want to use for my hardware project. The purpose of this relay is to function properly when the parking bar open and close. It is
cheap and small in size makes things easier to design it. (Figure 3.1 1)

Proximity Sensor

Figure 3.12(a): sensor

Figure 3.12(b): proximity sensor

These are Omron proximity Sensor that I m using for my project where by it w i l detect the presence of an object without physical contact. This proximity sensor is also known as high visibility indicator (Figure 3.12a and 3.12b).

CHAPTER fV

PROGRAMMABLE LOGIC CONTROLLER

4.1 PLC History

In the late 1960's PLCs were first introduced. The primary reason for designing
such a device was eliminating the large cost involved in replacing the complicated relay based machine control systems. Bedford Associates (Bedford, MA) proposed something called a Modular Digital Controller (MODICON) to a major US car manufacturer. Other companies at the time proposed computer based schemes, one of which was based upon
the PDP-8. The MODICON 084 brought the world's first PLC into commercial

production. When production requirements changed so did the control system. This becomes very expensive when the change is frequent. Since relays are mechanical devices they also have a limited lifetime which required strict adhesion to maintenance schedules. Troubleshooting was also quite tedious when so many relays are involved. Now picture a machine control panel that included many, possibly hundreds or thousands, of individual relays. The size could be mind boggling. How about the complicated initial wiring of so many individual devices! These relays would be individually wired together in a manner that would yield the desired outcome. Were there problems? You bet!

These "new controllers" also had to be easily programmed by maintenance and

piant engineers. The lifetime had to be long and programming changes easily performed. They also had to survive the harsh industrial environment. That's a lot to ask! The answers were to use a programming technique most people were already familiar with

and replace mechanical parts with solid-state ones.

In the mid70's the dominant PLC technologies were sequencer state-machines and
the bit-slice based CPU. The AMD 2901 and 2903 were quite ppular in Modicon and

A-B PLCs. Conventional microprocessors lacked the power to quickly solve PLC logic

in all but the smallest PLCs. As conventional microprocessors evolved, larger and larger PLCs were being based upon them. However, even today some are still based upon the 2903. (Ref A-B's PLC-3) Modicon has yet to build a faster PLC than their 984A/B/X which was based upon the 2901. Communications abilities began to appear in approximately 1973. The first such system was Modicon's Modbus. The PLC could now talk to other PLCs and they could be fBf.away from the actual machine they were controlling. They could also now be used to send and receive varying voltages to allow them to enter the analog world. Unfortunately, the lack of standardization coupled with continually changing technology has made PLC communications a nightmare of incompatible protocols and physical networks. Still, it was a great decade for the PLC! The 80's saw an attempt to standardize communications with General Motor's manufacturing automation protocol(MAP). It was also a time for reducing the size of the PLC and making them software programmable through symbolic programming on personal computers instead of dedicated programming terminals or handheld programmers. Today the world's smallest PLC is about the size of a single control relay! The W s have seen a gradual reduction in the introduction of new protocols, and the modernization of t k physical layers of some of the more popular protocols that survived the 1980's. The latest standard (IEC 1131-3) has tried to merge plc programming languages under one international standard. We now have PLCs that are programmable in function block diagrams, instruction lists, C and structured text all at the same time! PC's are also being used to replace PLCs in some applications. The original company who commissioned the MODICON 084 has actually switched to a PC based control system.

4.2 What is PLC

Figure 4.0 : Programmable Logic Controllers

A PLC (Programmable Logic Controller) is a device that was invented to replace

t e necessary sequential relay circuits for machine control. The PLC works by looking at h
its inputs and depending upon their state, turning on/off its outputs. The user enters a program, usually via software, that gives the desired results. PLCs are used in many "real world" applications. If there is industry present, chances are g o d that there is a plc present. If ycru are involved in machining, packaging, material handling, automated assembly or countless other industries you are probably already using them. If you are not, you are wasting money and time. Almost any application that needs some type of electrical control has a need for a plc. For example, let's assume that when a switch turns on we want to turn a solenoid on for 5 seconds and then t m it off regardless of how long the switch is on for. We can do this with a simple external timer. But what if the process included 10 switches and solenoid