Development of PLC-Based Controller for Pneumatic Pressing Machine in Engine-Bearing Manufacturing Plant

The paper reports design and development of a PLC-based controller for pneumatic pressing machine, which performs the most critical operation in an engine bearing manufacturing plant. The paper firstly overviews the manufacturing process of engine bearing and then discusses the need of automating the pneumatic press. The proposed automation system involves (a) speed control by replacing the conventional method with a variable frequency drive (VFD), (b) feeder and pusher control using PLC, (c) fault detection and safety measures, (d) and PLC-based sequential control of all the processes carried out on pneumatic press. The control system is based on MicroLogix-1000 PLC from Allen Bradley and the ladder logic program for it has been written on RSlogix-500. For the evaluation of the proposed control system, the PLC program was emulated on RSLogix Emulate-500 and the operations of the pneumatic press were simulated on FluidSIM-P. The results of simulation validate the design of PLC-based controller in general and digital input-output connections of the PLC and PLC program in particular.