A Model Of Traffic Light System By The Application Of PLC.
A MODEL OF TRAFFIC LIGHT SYSTEM BY THE
APPLICATION OF PLC
ZARIZAL BIN EDDY
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UNIVERSITI TEKNIKAL MALAYSIA MELAKA (UTeM)
A MODEL OF TRAFFIC LIGHT SYSTEM BY THE
APPLICATION OF PLC
Thesis submitted in accordance with the partial requirements of the Universiti Teknikal Malaysia Melaka for the
Bachelor of Manufacturing Engineering (Robotics & Automation)
By
ZARIZAL BIN EDDY
B 050410157
Faculty of Manufacturing Engineering May 2008
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UTeM Library (Pind.1/2007)
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PSM
JUDUL:A Model Of Traffic Light Syst em By t he Applicat ion Of PLC
SESI PENGAJIAN: Semest er 2 2007/ 2008
Saya Zarizal Bin Eddy mengaku membenarkan laporan PSM / t esis (Sarj ana/ Dokt or Falsaf ah) ini disimpan di Perpust akaan Universit i Teknikal Malaysia Melaka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :
1. Laporan PSM / t esis adalah hak milik Universit i Teknikal Malaysia Melaka dan
penulis.
2. Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan
unt uk t uj uan pengaj ian sahaj a dengan izin penulis.
3. Perpust akaan dibenarkan membuat salinan laporan PSM / t esis ini sebagai bahan
pert ukaran ant ara inst it usi pengaj ian t inggi.
4. *Sila t andakan (√)
SULIT
TERHAD
√ TIDAK TERHAD
(Mengandungi maklumat yang berdar j ah keselamat an at au kepent ingan Malaysia yang t ermakt ub di dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang t elah dit ent ukan oleh organisasi/ badan di mana penyelidikan di j alankan)
(TANDATANGAN PENULIS) Alamat Tet ap:
No 54, Taman Permai, Bandar Ceneh Baru, 24000 Kemaman, Terengganu.
(TANDATANGAN PENYELIA) Cop Rasmi:
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FAKULTI KEJURUTERAAN PEMBUATAN
Rujukan Kami (Our Ref) : 20 September 2012
Rujukan Tuan (Your Ref):
Pust akawan
Perpust akaan Universit i Teknikal Malaysia Melaka (UTeM) Taman Tasik Ut ama, Hang Tuah Jaya,
Ayer Keroh, 75450, Melaka Saudara,
PENGKELASAN LAPORAN PSM SEBAGAI SULIT/ TERHAD
- LAPORAN PSM SARJANA MUDA KEJURUTERAAN PEMBUATAN (ROBOTIC AND AUTOMATION): ZARIZAL BIN EDDY
TAJUK: A MODEL OF TRAFFIC LIGHT SYSTEM BY THE APPLICATION OF PLC
Sukacit a dimaklumkan bahawa t esis yang t ersebut di at as bert aj uk “ A model of
t raf f ic light syst em by t he applicat ion of PLC” mohon dikelaskan sebagai
t erhad unt uk t empoh lima (5) t ahun dari t arikh surat ini memandangkan ia mempunyai nilai dan pot ensi unt uk dikomersialkan di masa hadapan.
Sekian dimaklumkan. Terima kasih.
“ BERKHIDMAT UNTUK NEGARA KERANA ALLAH”
Yang benar,
………. . En. Ruzaidi bin Zamri
Pensyar ah,
Fakul t i Kej ur ut er aan Pembuat an
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
Karung Berkunci 1200, Ayer Keroh, 75450 Melaka
Tel : 06-233 2421, Faks : 06 233 2414 Email : fkp@kutkm.edu.my
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APPROVAL
This thesis submitted to the senate of UTeM and has been accepted as fulfillment of the requirement for the Bachelor of Manufacturing Engineering (Robotic and Automation).
The members of the supervisory committee are as follows:
………. (Mr. Ruzaidi bin Zamri)
Main supervisor
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DECLARATION
I hereby, declare this thesis entitled “A Model Of Traffic Light System By The Application Of PLC” is the result of my own research except as cited in the
references.
Signature : ………
Author’s Name : Zarizal Bin Eddy
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ABSTRACT
The project that was developed is “A model of traffic light system by the application of PLC”. This is one of the applications from the existing traffic light system in Malaysia. This model is integrated with PLC Keyence KV series. It uses three PLC which every PLC have ten input and six output. For this model it uses two input and eighteen output. It have start button to start operating the system and stop button to terminate the operation of the system. The system can be monitor on control panel because the path that moving will be indicate by the indicator light for every traffic light 1, traffic light 2, traffic light 3 and traffic light 4. This application is come from the sequence that been program in PLC by ladder diagram. To implement the development of this prototype, many steps have to perform. Starts with project planning, information searching and then further with prototype construction, there are been manage well until the recent progression that lead the way to produce a final functional prototype of a model of traffic light by the application of PLC.. By analyze and study about the previous researches, its help more to understand the concept and the application to be use for this prototype. This Project can be categorized to three main criteria which is mechanical, electrical and programming.
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ii
ABSTRAK
Projek yang telah di bangunkan ini bertajuk “Satu model sistem lampu isyarat yang menggunakan aplikasi PLC. Model ini adalah terhasil daripada sistem lampu isyarat yang sedia ada di Malaysia. Model ini diintegerasikan dengan PLC siri Keyence KV. Sistem ini menggunakan tiga PLC yang mana setiapnya mempunyai sepuluh input dan enam output. Untuk model ini, ianya menggunakan kesuluruhan dua input dan lapan belas output. Ianya mempunyai butang mula untuk memulakan operasi sistem dan butang berhenti untuk memberhentikan sistem. Sistem lampu isyarat ini dapat di perhatikan daripada kotak kawalan kerana laluan yang sedang bergerak akan dapat diperhatikan pada lampu penanda untuk laluan satu, lauan dua, laluan tiga dan laluan empat. Aplikasi di janakan melalui turutan yang telah di programkan pada PLC iaitu melalui gambarajah tangga. Untuk menghasilkan prototaip ini banyak langkah- langkah yang perlu di jalankan. Ianya bermula dengan perangkaan projek, carian maklumat dan seterusnya kepada pembinaan prototaip yang seperti yang di rancangkan sehingga terhasilnya model ini. Dengan mengkaji dan menganalisis daripada kajian sebelum ini ianya lebih membantu untuk memahami konsep dan aplikasi untuk digunakan bagi menghasilkan prototaip lampu isyarat ini. Projek ini boleh di bahagikan kepada tiga kategori utama iaitu mekainal, elektrikal dan pemogramman.
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DEDICATION
For my parents, my beloved late father Allahyarham Eddy Bin Lassim and my mother, Unang Binti yatim, for my siblings and friends.
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ACKNOWLEDGEMENTS
The Name of Allah, The Most Gracious and Merciful.
Alhamdulillah, praise to The Almighty Allah SWT who gave me the strength to complete this project. Firstly, I would like to express my gratefulness towards Allah S.W.T because giving me the opportunity to finish my final year project. Without faith towards the almighty, I would not have the confidence to finish this project. I would like to thank my beloved family especially my mother, Mrs. Unang Binti Yatim and my siblings for showing love, support and advice when in truly need. I would like also to express my greatest appreciations to my wise supervisor, Mr. Ruzaidi bin Zamri, truly without his guidance, I would have been lost. Not to forget to thank the technicians who gave me a lot of assistance and information. Not forget to my friends for their attention and also many thanks to all my lecturers and staffs who showed support and willing to help in finishing my thesis project. Thank you very much.
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TABLE OF CONTENT
Content List Page
Abstract i
Dedication iii
Acknowledgements iv
Table of Contents v
List of Figures ix
List of Tables xii
List of Abbreviations, Symbols, Specialized Nomenclature xiii
1. INTRODUCTION 1
1.1 Problem Statement 3
1.2 Aims/ objective 4
1.3 Scope 4
1.4 Significant of Study 4
1.5 Conclusion 5
2. LITERATURES REVIEW 6
2.0 Introductions 6
2.1 Programmable Logic Control (PLC) 7
2.1.1 Introduction 7
2.1.2 Features 8
2.1.3 Recent project using PLC 10
2.2 Traffic Light 11
2.2.1 Introduction 11
2.2.2 Features 12
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vi
2.3 Recent Project 15
2.3.1 Intelligent Traffic Lights Control by Fuzzy Logic 15
2.3.2 Majlis Perbandaran Kota Baru 16
2.3.3 Control of vehicular traffic through a sequence of traffic lights positioned with disordered interval 19
2.3.4 An urban traffic network model via coloured time Petri net 19
2.4 Conclusion 20
3. METHODOLOGY 21
3.0 Introduction 21
3.1 Programming approach 22
3.2 Development Phase 23
3.2.1 Gantt Chart 23
3.2.2 Project flow description 25
3.2.3 Flow Chart 26
3.3 Equipment Being Selected 28
3.3.1 Control system 28
3.3.1.1 Keyence PLC 28
3.3.1.2 Software 30
3.3.2 Electrical component 32
3.3.2.1 Power Supply (AC to DC) 32
3.3.2.2 Plug 32
3.3.2.3 Wire 33
3.3.2.4 Maintained push button switch 34
3.3.2.5 Emergency pushbutton switches 35
3.3.2.6 Light indicator 36
3.3.2.7 Terminal block 37
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3.3.3.1 Din rail 38
3.3.3.2 Screw 38
3.3.3.3 Acrylic 39
3.4 Technique 40
3.4.1 Base construction 40
3.4.2 Wiring 42
3.4.3 Programming 43
3.5 Tool 45
3.5.1 Jig saw 45
3.5.2 Hand drill 46
3.5.3 Hole saws 47
3.5.3 Super glue 47
3.6 PLC compared with other control systems 48
3.7 Conclusion 49
4. RESULT 50
4.0 Introduction 50
4.1 Mechanical construction 52
4.1.1 Base 52
4.1.2 Traffic light 54
4.2 Electrical 55
4.2.1 PLC Communication Cable 55
4.2.2 Wiring 57
4.2.3 Wire marking 62
4.3 Programmable logic control 63
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viii
4.3.1 List of input/output 63
4.3.2 Timing Chart 64
4.3.4 Programming 66
4.3.4.1 PLC 1 66
4.3.4.1 PLC 2 67
4.3.4.1 PLC 3 69
4.4 Conclusion 70
5. DISCUSSION 71
5.0 Introduction 71
5.1 Problem encounter 72
5.1.1 Programming 72
5.1.2 PLC wiring 75
5.1.3 Design for programming 76
5.2 Finding 78
5.2.1 Keyence PLC KV series 78
5.2.2 Timing chart 78
5.2.3 Process sequence 78
5.3 Conclusion 80
6. CONCLUSION 81
6.0 Conclusion 81
6.1 Recommendation and future work 81 REFERRENCE 83
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APPENDICES 84 A Drawing base for laser cutting process
B Timing chart
C Ladder diagram for PLC 1 D Ladder diagram for PLC 2 E Ladder diagram for PLC 3
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x
LIST OF FIGURE
Content List Page 2.1 The first signal tower with automatic lights, at Michigan and Woodward 11
2.2 Traffic light model 13
2.3 A general structure of the fuzzy traffic light control system 15
2.4 Induction loop traffic sensors 16
2.5 The traffic light that uses the sensor 17
2.6 Main Switch Board and Controller System 17
2.7 PLC Controller System 18
2.8 Metal Detector Sensor under the Road Pavement 18
3.1(a) Flow chart of overall flow process for PSM 1 26
3.1(b) Flow chart of overall flow process for PSM 2 27
3.2 Keyence PLC 28
3.3 LBK software 30
3.4 KV builder ladder 30
3.5 Power supply 32
3.6 Plug 32
3.7 Wire 33
3.8 Start button 34
3.9 Emergency stop button 35
3.10 Light indicator 36
3.11 Terminal block 37
3.12 Din rail 38
3.13 Screw 38
3.14 Acrylic 38
3.15 Main acrylic board 40
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3.17 Join between top and edge 41
3.18 Wire markers 42
3.19 Jig saw 45
3.20 Hand drill 46
3.21 Hole saws 47
3.22 Super glue 47
4.1 Complete model 50
4.2 Complete model with device name 51
4.3 Base 52
4.4 Laser cutting process 52
4.5 Traffic light assembly 54
4.6 Light indicator mount to traffic light 54
4.7 Wire positions 55
4.8 Soldering process 55
4.9 PLC communication cable 56
4.10 Electrical circuit for PLC 1 57
4.11 Electrical circuit for PLC 2 58
4.12 Electrical circuit for PLC 3 58
4.13 Wiring below the model system 59
4.14 Wiring for PLC and terminal block 60
4.15 Wiring in traffic light box 60
4.16 Wire marking 62
4.17 Timing chart 64
4.18 Ladder diagram for PLC 1 66
4.19(a) Ladder diagram for PLC 2 67
4.19(b) Ladder diagram for PLC 2 68
4.20(a) Ladder diagram for PLC 3 69
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xii
5.1 Keyence KV series 72
5.2 Help instruction 73
5.3 Setting for timer 73
5.4 Ladder diagram 74
5.5 Wiring for input and output 75
5.6 Connection for PLC to combine in one system 76
5.7 Three PLC being use 77
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LIST OF TABLE
Content List Page
3.1 Gantt chart for PSM 1 23
3.2 Gantt chart for PSM 2 24
3.3 Keyence PLC product description 29
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xiv
LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED
NOMENCLATURE
PLC - Programmable Logic Control
NEMA - National Electrical Manufacturer Association SCADA - Supervisory Control and Data Acquisition ATC - Advanced transportation controller
PID - Proportional integral controller
DCS - Distributed control system
I/O - Input and output
LED - Light emitting diode
HSS - High Speed Steel
nm - Nanometer
mm - millimeter
φ - Diameter
DC - Direct current
AC - Alternating current
V - Volt
A - Ampere
NO - Normally open
NC - Normally closed
“ - Inch
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CHAPTER 1
INTRODUCTION
1.0 Introduction
Traffic light which is one of the vital public facilities plays an important role to the road users. It will help to curb from accidents and gridlocks. This research exposed the operational of traffic light such as understanding the flow of the traffic system and the program itself. Traffic signal light is used to control the movement of vehicles and passengers, so that traffic can flow smoothly and safely. Traffic signal lights have been around for years and are used to efficiently control traffic through intersections. Although traffic signal lights are relatively simple and commonplace, they are critical for ensuring the safety of the driving area. The growing use of traffic lights attests to their effectiveness in directing traffic flow, reducing the number of accidents, and the most recently to their utility in controlling the flow of traffic through metropolitan areas when have been used together with computer systems.
Traffic signal lights will improve the road safety and reduce congestion by providing the signals orderly through junctions. Traffic control lights are provided for traffic control on streets and highways, especially at junctions. The traffic signals are cyclically displayed through a suitable timing and control mechanism. A traffic light has three colors which are red, yellow and green. Every color carries a certain sign. The red light means the road user has to stop driving and not crossing or pursuing the ride while the yellow light show that the road user has to ready to stop their ride. However if the user is too close to the line that is not safe for a stop they have to continue the ride. The
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2
green light shows the road user can continue their journey only with the absence of any hindrance. Driving through a red light without justification may be a citation able traffic offense. The transition of the light is controlled by PLC to help the traffic movement run smooth from one direction to the other. PLC reduces traffic congestion especially in the morning and evening. Besides, it also helps to reduce the accident rate especially in town.
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1.2 Problem Statement
According to Kok, K. T. et al (1996a), the monitoring and control of city traffic is becoming a major problem in many countries. With the ever increasing number of vehicles on the road, the Traffic Monitoring Authority or the Transport Ministry as the authority has to find new ways or measurements of overcoming this kind of problem. The measures had be taken were development of new roads and flyovers in the middle of the city, building of several ring such as the inner ring road, middle ring road and outer ring road, introduction of city trains such as the light rapid transit (LRT), and monorails, restricting of large vehicles in the city during peak hours, and also development of sophisticated traffic monitoring and control systems. In the city of Kuala Lumpur, the registration of new vehicles each year increased by about twenty per cent. This increment is rather alarming and even with the development of the LRT and new roads other measures have to be stepped up and introduced as quickly as possible. In Kuala Lumpur the problem of traffic flow during peak hours has been under control by the city traffic police. Traffic management systems address the objective of reducing congestion, vehicle delay time, fuel consumption and pollution (Mariagrazia Dotoli, 2006a). The transition of the light is controlled by PLC to help the traffic movement run smooth from one direction to the other. There is little reason to automate the traffic light using PLC. Compare to the conventional control panel there is too much wiring work in the panel. Troubleshooting can be quite troublesome and may require a skillful person. Modification of control sequence or application can easily be done by proggramming through the console or computer software without changing I/O wiring, if no additional input or output devices are required. Drawings for conventional control panel are not updated over the years due to changes, it will causes longer downtime in maintenance and modification. Futhermore, machine downtime is usually long when problems occur, as it take a longer time to troubleshoot the control panel. In PLC system spare part or relays and hardware timers are greatly reduced as compared to conventional control panel. Then, power consumption can be quite high as the coil of conventional control panel consumes power (Omron, 2000a).
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4 1.3 Aims/ Objective
The objective of this project is:
• To develop and design a traffic light system using PLC. • Create prototype for traffic light model
• Develop ladder diagram using Keyence PLC
1.4 Scope
The scope of this project will be cover on the design and programming of a crossroad traffic light system. The design work will include the application of Solid work and Autocad software. On the programming part, programmable logic controller will be used to integrated with the hardware or model that will be develop.
1.5 Significant of Study
Traffic light is the common use in our journey. Experience and knowledge is required to explore this system. This project is the combination of three main enginerring field which is mechanical, electric and electronic and computer programming. The usage of PLC in this project give an exposure on how to automate the system.
In construction the ladder diagram, creativity and innovativity are need to make a design although in creating design prototype. All the consideration must be count to complete this project. This system will be act as the countermeasure of traffic jammed at junction.
The combination of theoritical and hands on will exposing to the reality of the enginerring world. This project also approach how to generate and get the information from many sources. It is also an approach to improve the communication skills to public due to the project. Based on the gantt chart, it will guiding on how to manage time and
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LIST OF TABLE
Content List Page
3.1 Gantt chart for PSM 1 23
3.2 Gantt chart for PSM 2 24
3.3 Keyence PLC product description 29
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LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED
NOMENCLATURE
PLC - Programmable Logic Control
NEMA - National Electrical Manufacturer Association SCADA - Supervisory Control and Data Acquisition ATC - Advanced transportation controller
PID - Proportional integral controller DCS - Distributed control system
I/O - Input and output
LED - Light emitting diode
HSS - High Speed Steel
nm - Nanometer
mm - millimeter
φ - Diameter
DC - Direct current
AC - Alternating current
V - Volt
A - Ampere
NO - Normally open
NC - Normally closed
“ - Inch
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CHAPTER 1
INTRODUCTION
1.0 Introduction
Traffic light which is one of the vital public facilities plays an important role to the road users. It will help to curb from accidents and gridlocks. This research exposed the operational of traffic light such as understanding the flow of the traffic system and the program itself. Traffic signal light is used to control the movement of vehicles and passengers, so that traffic can flow smoothly and safely. Traffic signal lights have been around for years and are used to efficiently control traffic through intersections. Although traffic signal lights are relatively simple and commonplace, they are critical for ensuring the safety of the driving area. The growing use of traffic lights attests to their effectiveness in directing traffic flow, reducing the number of accidents, and the most recently to their utility in controlling the flow of traffic through metropolitan areas when have been used together with computer systems.
Traffic signal lights will improve the road safety and reduce congestion by providing the signals orderly through junctions. Traffic control lights are provided for traffic control on streets and highways, especially at junctions. The traffic signals are cyclically displayed through a suitable timing and control mechanism. A traffic light has three colors which are red, yellow and green. Every color carries a certain sign. The red light means the road user has to stop driving and not crossing or pursuing the ride while the yellow light show that the road user has to ready to stop their ride. However if the
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green light shows the road user can continue their journey only with the absence of any hindrance. Driving through a red light without justification may be a citation able traffic offense. The transition of the light is controlled by PLC to help the traffic movement run smooth from one direction to the other. PLC reduces traffic congestion especially in the morning and evening. Besides, it also helps to reduce the accident rate especially in town.
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1.2 Problem Statement
According to Kok, K. T. et al (1996a), the monitoring and control of city traffic is becoming a major problem in many countries. With the ever increasing number of vehicles on the road, the Traffic Monitoring Authority or the Transport Ministry as the authority has to find new ways or measurements of overcoming this kind of problem. The measures had be taken were development of new roads and flyovers in the middle of the city, building of several ring such as the inner ring road, middle ring road and outer ring road, introduction of city trains such as the light rapid transit (LRT), and monorails, restricting of large vehicles in the city during peak hours, and also development of sophisticated traffic monitoring and control systems. In the city of Kuala Lumpur, the registration of new vehicles each year increased by about twenty per cent. This increment is rather alarming and even with the development of the LRT and new roads other measures have to be stepped up and introduced as quickly as possible. In Kuala Lumpur the problem of traffic flow during peak hours has been under control by the city traffic police. Traffic management systems address the objective of reducing congestion, vehicle delay time, fuel consumption and pollution (Mariagrazia Dotoli, 2006a). The transition of the light is controlled by PLC to help the traffic movement run smooth from one direction to the other. There is little reason to automate the traffic light using PLC. Compare to the conventional control panel there is too much wiring work in the panel. Troubleshooting can be quite troublesome and may require a skillful person. Modification of control sequence or application can easily be done by proggramming through the console or computer software without changing I/O wiring, if no additional input or output devices are required. Drawings for conventional control panel are not updated over the years due to changes, it will causes longer downtime in maintenance and modification. Futhermore, machine downtime is usually long when problems occur, as it take a longer time to troubleshoot the control panel. In PLC system spare part or relays and hardware timers are greatly reduced as compared to conventional control panel. Then, power consumption can be quite high as the coil of conventional control
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1.3 Aims/ Objective The objective of this project is:
• To develop and design a traffic light system using PLC. • Create prototype for traffic light model
• Develop ladder diagram using Keyence PLC
1.4 Scope
The scope of this project will be cover on the design and programming of a crossroad traffic light system. The design work will include the application of Solid work and Autocad software. On the programming part, programmable logic controller will be used to integrated with the hardware or model that will be develop.
1.5 Significant of Study
Traffic light is the common use in our journey. Experience and knowledge is required to explore this system. This project is the combination of three main enginerring field which is mechanical, electric and electronic and computer programming. The usage of PLC in this project give an exposure on how to automate the system.
In construction the ladder diagram, creativity and innovativity are need to make a design although in creating design prototype. All the consideration must be count to complete this project. This system will be act as the countermeasure of traffic jammed at junction.
The combination of theoritical and hands on will exposing to the reality of the enginerring world. This project also approach how to generate and get the information from many sources. It is also an approach to improve the communication skills to public due to the project. Based on the gantt chart, it will guiding on how to manage time and