Learning outcomes

The tasks within this assignment satisfy the Learning Outcomes of the course according to the table below:

1. Design, implement, test, and document PLC programs to solve defined or undefined industrial automation control problems.
2. Integrate, configure, and troubleshoot a range of field devices with PLC systems to solve advanced industrial automation control problems.

Demonstrate advanced knowledge of PLC-controlled processes by testing program functionality, interpreting results, and explaining design decisions.

Instructions for Exams (Open book)

Show all your work clearly. Answers must have clearly stated units. Use diagrams where applicable.

Any assumptions should be clearly stated.

You must keep a copy of the final draft of the assignment. You should declare that the submitted work is your own.

Plagiarized work will receive the appropriate penalties as set out in Bahrain Polytechnic Policy. You are responsible for the complete submission of your assignment(s).

This work can be used for moderation purposes.

This work may be submitted to Turnitin and if so, it will be stored in the Turnitin database for comparison purposes.

Instructions for Submission Exams (Open book):

The assessment will be available under the link below onto the courses Moodle page

https://moodle.polytechnic.bh/moodle/course/modedit.php?update=286060&return=0&sr=4

After the deadline, answers submitted by other methods will not be accepted.

Instructions specifically for this project:

• Based on the specification below, produce a PLC RSLogix5000 project that will provide the required
• Ensure sufficient comments to your PLC program is provided and produce a short report with a brief explanation about the program functionality with pictures of the prototype in report format.
• You must present/demonstrate the project individually, at the given time, and within a given time limit (15 mins). A soft copy of all project documents is required before your presentation/demonstration.
• Your project files must be submitted on
• Project prototype (Box)

Task Specification Project

Automated Industrial Warehouse Facility Management and Control System:

The Automatic industrial warehouse facility management system automatically controls access gates and turnstiles, manages zone lighting and HVAC setpoints, displays real-time zone space and triggers alarms and emergency procedures during incidents and water and drainage control all based on real-time inventory, personnel presence, and operational conditions across the facility. A sample layout and workflow for the warehouse facility management system are illustrated in Figure 1

Figure.1 Automatic Industrial Warehouse Facility Management and control system

Note: 1. Please ensure that all necessary input and output tags are accurately included.

2. Students may select the appropriate PLC languages for both the design and implementation phases of the project.

Upon entering the run mode, all counters/timers must be reset (use the first scan bit).

Part 1: The lighting control system reduces energy consumption while maintaining appropriate illumination. The warehouse is divided into three zones, and each zones lighting is controlled by a dedicated motion sensor (for example, Sensor 1 controls Zone 1 lighting).

• Motion sensors switch zone lighting ON when occupancy is detected and turn it off after a delay of 3 seconds.
• Daylight sensors dim or reduce artificial lighting during When Daylight sensor is ON, the rooftop sliding door is opened by the roof motor it will be stopped after roof limit switch turns on).

Part 2: The HVAC and ventilation system maintains temperature and air quality across the warehouse. The facility has two HVAC units that serve all three zones. Their operation is as follows:

• When the temperature rises above 30C, HVAC 1 will start HVAC 2 will start after a 5-second delay.
• If the temperature exceeds 40C, HVAC 1 will turn off and HVAC 2 will run; HVAC 1 will then restart after a 10-second delay.
• If the temperature has gone above 40C and is subsequently reduced below 40C by the HVAC system, HVAC 2 will turn off after a 10-second delay and HVAC 1 will remain ON until the temperature drops below 30C.

Additionally, if humidity or gas levels rise above their configured limits at any time, the exhaust fans will start and continue operating until the readings return below the set points

Note: An up counter (CTD) can be used to represent the warehouse temperature.

Part 3: If smoke is detected inside the warehouse while the exhaust fans are running, the fans will stop immediately, and the exit gates will open to allow people to evacuate. The fire alarm will sound continuously with a 65% duty cycle over a 6-second period, the emergency exit lights will turn ON, and the water sprinklers will activate.

When the fire detection sensor is cleared:

• The emergency exit lights will be turned off
• The fire alarm will stop after a 3-second
• The water sprinklers will deactivate 5 seconds after the fire alarm

Part 4: The rack management system uses a photo-detection sensor to count the number of racks entering the warehouse. Each zone contains 10 racks.

• If the rack count is greater than 0, Zone 1 LED (Green) will blink (3 seconds on, 2 seconds off). When the rack count reaches 10, the Zone 1 LED will stop blinking and remain continuously on. The display will show the current occupancy percentage for Zone 1 (0% to 33%).
• If the rack count is greater than 10 and less than or equal to 15, Zone 2 LED (Amber) will turn on and the green LED (Zone 1) will turn off after a 4-second delay.
• If the rack count is greater than 15 and less than or equal to 20, Zone 2 LED (Amber) will blink (3 seconds off, 2 seconds on). The display will show the current occupancy percentage for Zones 1 2 (34% to 66%).
• If the rack count is greater than 20, Zone 3 LED (Red) will blink (5 seconds on, 3 seconds off) and the amber LED (Zone 2) will turn off When the rack count reaches 30, Zone 3 LED will remain continuously on. The display will show the current occupancy percentage for Zones 1 3 (67% to 100%).

Part 5: The water and drainage management system monitors tank levels, automatically controls pumps, and detects leaks to protect the facility.

Tank level sensing: Three level sensors monitor each tank: Level 1, Level 2, and Level 3.

• Level1 indicates the tank is empty (0%).
• Level2 indicates the tank is above 40%.
• Level3 indicates the tank is full (100%). A green LED represents tank status.

Pump control and LED behavior:

If the tank level falls to 0% (Level 1 active), the water pump is activated and runs continuously to fill the tank.

• When the level is up to 40% (Level 2 inactive and Level 1 active), the green LED blinks with a 20% duty cycle over a 10-second period.
• When the level is above 40% (Level 2 active but below 100%), the green LED blinks with an 80% duty cycle over a 5-second period.
• When the tank reaches 100% (Level 3 active), the green LED remains continuously on, and the water pump stops immediately.

Backup and fault handling: Backup pumps engage automatically if a primary pump fails.

Leak detection: Leak sensors located near tanks, pumps, drains, and critical equipment trigger audible and visual alarms when moisture or leakage is detected.

Marking Rubric

Presentation / Demonstration Marking Rubric.

Note: 1. Please ensure that all necessary input and output tags are accurately included.

2. Students may select the appropriate PLC languages for both the design and implementation phases of the project.

Upon entering the run mode, all counters/timers must be reset (use the first scan bit).

Part 1: The lighting control system reduces energy consumption while maintaining appropriate illumination. The warehouse is divided into three zones, and each zones lighting is controlled by a dedicated motion sensor (for example, Sensor 1 controls Zone 1 lighting).

• Motion sensors switch zone lighting ON when occupancy is detected and turn it off after a delay of 3 seconds.
• Daylight sensors dim or reduce artificial lighting during When Daylight sensor is ON, the rooftop sliding door is opened by the roof motor it will be stopped after roof limit switch turns on).

Part 2: The HVAC and ventilation system maintains temperature and air quality across the warehouse. The facility has two HVAC units that serve all three zones. Their operation is as follows:

• When the temperature rises above 30C, HVAC 1 will start HVAC 2 will start after a 5-second delay.
• If the temperature exceeds 40C, HVAC 1 will turn off and HVAC 2 will run; HVAC 1 will then restart after a 10-second delay.
• If the temperature has gone above 40C and is subsequently reduced below 40C by the HVAC system, HVAC 2 will turn off after a 10-second delay and HVAC 1 will remain ON until the temperature drops below 30C.

Additionally, if humidity or gas levels rise above their configured limits at any time, the exhaust fans will start and continue operating until the readings return below the set points

Note: An up counter (CTD) can be used to represent the warehouse temperature.

Part 3: If smoke is detected inside the warehouse while the exhaust fans are running, the fans will stop immediately, and the exit gates will open to allow people to evacuate. The fire alarm will sound continuously with a 65% duty cycle over a 6-second period, the emergency exit lights will turn ON, and the water sprinklers will activate.

When the fire detection sensor is cleared:

• The emergency exit lights will be turned off
• The fire alarm will stop after a 3-second
• The water sprinklers will deactivate 5 seconds after the fire alarm

Part 4: The rack management system uses a photo-detection sensor to count the number of racks entering the warehouse. Each zone contains 10 racks.

• If the rack count is greater than 0, Zone 1 LED (Green) will blink (3 seconds on, 2 seconds off). When the rack count reaches 10, the Zone 1 LED will stop blinking and remain continuously on. The display will show the current occupancy percentage for Zone 1 (0% to 33%).
• If the rack count is greater than 10 and less than or equal to 15, Zone 2 LED (Amber) will turn on and the green LED (Zone 1) will turn off after a 4-second delay.
• If the rack count is greater than 15 and less than or equal to 20, Zone 2 LED (Amber) will blink (3 seconds off, 2 seconds on). The display will show the current occupancy percentage for Zones 1 2 (34% to 66%).
• If the rack count is greater than 20, Zone 3 LED (Red) will blink (5 seconds on, 3 seconds off) and the amber LED (Zone 2) will turn off When the rack count reaches 30, Zone 3 LED will remain continuously on. The display will show the current occupancy percentage for Zones 1 3 (67% to 100%).

Part 5: The water and drainage management system monitors tank levels, automatically controls pumps, and detects leaks to protect the facility.

Tank level sensing: Three level sensors monitor each tank: Level 1, Level 2, and Level 3.

• Level1 indicates the tank is empty (0%).
• Level2 indicates the tank is above 40%.
• Level3 indicates the tank is full (100%). A green LED represents tank status.

Pump control and LED behavior:

If the tank level falls to 0% (Level 1 active), the water pump is activated and runs continuously to fill the tank.

• When the level is up to 40% (Level 2 inactive and Level 1 active), the green LED blinks with a 20% duty cycle over a 10-second period.
• When the level is above 40% (Level 2 active but below 100%), the green LED blinks with an 80% duty cycle over a 5-second period.
• When the tank reaches 100% (Level 3 active), the green LED remains continuously on, and the water pump stops immediately.

Backup and fault handling: Backup pumps engage automatically if a primary pump fails.

Leak detection: Leak sensors located near tanks, pumps, drains, and critical equipment trigger audible and visual alarms when moisture or leakage is detected.

Marking Rubric

Presentation / Demonstration Marking Rubric.

Project- Automatic Industrial warehouse facility Management Control System

System Functionality

Plagiarism & Collusion

WARNING ON PLAGIARISM & COLLUSION

Plagiarism is defined as the misrepresentation of another person's ideas, thoughts or words as though they were your own. All types of deliverables are covered by this definition, including written work, diagrams, designs, engineering drawings and pictures.

At Bahrain Polytechnic, we encourage independent thinking and you are entitled to criticize other peoples work and include it in your report.

However, you MUST acknowledge your sources. This can be achieved by quoting and citing the published or unpublished work of others, which include sources from the internet, books, journal articles, conference proceedings, and any other credible or uncredible sources. A full reference to the source must be provided in an appropriate format and should be included in your References/Bibliography section of your report.

Collusion is defined as an unauthorized conscious collaboration between two or more students in producing work that is deemed to be identical or largely similar in content and representing the work as though they were their own.

If a tutor suspects a plagiarism and/or collusion offence in a report, then this may result in an allegation of cheating. Such cases will be dealt with under the Bahrain Polytechnic's procedure and may result in a severe penalty being taken against any student found guilty and it may result in the student being expelled from the course indefinitely.

Departments are able to give advice about the appropriate use and correct acknowledgements of other sources in your own work.