Simulation and Modelling of 3-Floor Elevator System using PLC

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 06 | Jun 2022 www.irjet.net p-ISSN: 2395-0072
© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 2882
Simulation and Modelling of 3-Floor Elevator System using PLC
Ajith Srikanth1, V Nehaa2
1,2Student, B. Tech in Mechatronics Engineering, SRMIST, Kattankulathur, Chennai - 603203, Tamil Nadu, India
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Abstract - Elevators are a common vertical mode of
transport in buildings, warehouses, construction sites, etc.
The elevator's design and mechanics undergo continuous
modification to make it more efficient and inexpensive for
daily use. The design of the elevator based on the
Programmable Logic Controller is one such innovation
(PLC). Despite the fact that contemporary elevators are not
exclusively controlled by PLC, this field has great potential
to become the future of the elevator industry. PLC is a solid-
state device whose response is dependent on the user-
defined program's input. PLC-based elevators have
improved the current elevator systems by eliminating the
need for a machine room. Due to its compact system and
programmable PLC, elevators can be utilized in a number of
different fields. The primary objective of this research was to
demonstrate the modeling of elevator motion using PLC
ladder logics.
Key Words: Elevator Control, Function Block
Diagram, Ladder Logic, PLC, TIA Portal.
1. INTRODUCTION
All-solid-state PLCs respond to user input in response to
instructions. Industrial Microcontrollers have hardware
and software tailored to industrial needs. They supply
data-analyzers for automated production and service
lines. Systems controlled by microprocessors and PLCs
can be found in elevators. Programming is usually done on
a personal computer in ladder logic. Reprogramming PLC
controllers is often done on a computer, but it can also be
done manually with programmes. The aim is to control the
elevator using PLC. It's easy to use and PLC-upgradable.
Conventional elevators require a lot of space and a
maintenance room. Building shorter or smaller elevators
is difficult. PLC-based elevators are easier to maintain,
cheaper, and can be upgraded as needed. Following the
execution of the user programme that has been saved in
application memory, the PLC will either activate or
deactivate field output devices depending on the control
scheme that has been loaded into the PLC.
1.1 Principle
The user's control scheme is interpreted by the PLC, which
then activates or deactivates field output devices, reads all
field input devices through input interfaces, and executes
the user programme stored in application memory.
Mechanical and maintenance space is needed for
conventional elevators. Shorter/smaller buildings can't
install elevators. Easy-to-maintain, cost-effective, and
upgradeable PLC elevators. Despite improvements,
elevators are hard to install and maintain. PLC-based
elevator systems reduce elevator size, making them easier
to maintain, reprogram, and access.
Fig. 1 Block Diagram of PLC Elevator Control
1.2 Pros and Cons
The use of a PLC system comes with a number of benefits,
including its compact size, the ability to be reprogrammed
and customized, and the simplicity with which the
application can be replicated and documented. PLC
manufacturers only offer a closed-loop architecture, which
is one of the system's disadvantages, as well as the fact
that it runs on a predetermined circuit.
Fig. 2 Understanding the Flow

1.3 Terminologies
PLC language uses some unique terms that are different
from terms that are used daily. In order to understand the
working of the ladder logic there is a need to understand
some of the terms that are mentioned below:
1. Central Processing Unit (CPU) - It is the PLC
controller's brain. It is one of the microcontrollers and
is responsible for communication and interconnection
with other sections of the PLC controller, as well as
program execution, memory operation, input
monitoring, and output setup.
2. Memory - PLC has two types of memories used namely
a. Read Only Memory (ROM) - The memory
location which stores the symbols and other
information necessary while the execution of
the program.
b. Random Access Memory (RAM) - The
memory location that stores the calling
functions based on the ladder logics.
3. Power Supply - The power necessary for the PLC to
perform all the functions that are necessary was
provided through an AC source. A 240V SMPS is used
in the simulation.
4. I/O module: The I/O module is a Rack that provides all
the Necessary information to both the PLC and the
user. It provides the address of all the inputs and
outputs.
5. Programming Devices:
a. Ladder Logic Diagram (LAD) - It is a step
diagram of the Logics that is proposed for the
working of the elevator. It uses Symbols and
components of the element in a line diagram
that shows the hard wire control.
b. Statement List (STL) - It is another view of the
instructions provided to the PLC in the form
of text. The operation is shown to the left and
the operand is shown to the right.
c. Function Block Diagram (FBD) - It is a set of
instructions in the form of a block diagram.
The functions are indicated by a rectangle and
have a specific task.
6. Interfacing Devices
The interfacing Devices available for the PLC are given
below:
a. Profibus
Point to Point Interface – USB
Multipoint Interface - USB
b. Profinet
Ethernet - The Interfacing Devices used are
TCP/IP which is a collection protocol used for
communication. It consists of 3 components: IP,
TCP and UDP.
Fig. 3 Symbol Table
2. METHODOLOGY
After careful investigation, some characteristics including
motor ratings and automobile weight were calculated. PLC
CPU requirements were dependent on DC Motor and rope
strength. Some knowledge on software compatibility and
usability were required since it is simulation-based. For a
rudimentary implementation, the use of switches and logic
like AND, NAND, OR, and XOR with NC and NO LAD
switches. The inputs observed are 6 signals namely Car
Location, Floor Buttons, Car Buttons, Car Movement
(Direction), Door Status, and Signal Triggers. This signal is
represented by the HMI Toolbox Button. With these
factors in mind, the ladder logics were created and
simulated.
2.1 Sequence of Operation
The PLC continuously carries out 3-4 basic steps namely
Error Check, Input scan, Logic scan, Output scan. Before
running the program, the software checks for any

presence of any error. Input Scan is known as the inputs
provided by the user are scanned by the plc and stored in
the memory. Logic scan is the CPU of the PLC is the
controller of the logic. It reads inputs, executes the
programme step-by-step, and updates output. Output scan
is the logic scan's final presentation from memory.
Fig. 4 Flowchart of the Process
2.2 Components
1. Power Supply
2. PLC S-Series 315
3. Simulation Software:
a. Siemens PLCSIM
b. Siemens Simatic Manager
c. Siemens TIA portal
d. Siemens WinCC Viewer
e. Siemens Step 7
4. Ladder Logic Circuits
5. Display Module
6. Switches, Sensors and Elevator Car
2.3 Calculations
Calculations helped choose simulation components for the
hardware implementation. In order to reduce the
elevator's cost, the most versatile and reliable parts were
needed.
Car Specification:
Weight of the cabin = 100 kg
Counter weight = 100 kg
Limit of 10 people each weighing 65 kg = 650kg
Rope strength:
F= mg ; F= (650+100+100) *9.8 = 8330N = 8.33 KN Motor
Specification:
Power:
P= Force*Velocity; P= (650*9.8) N*1m/s = 6370W
Since, 1hp = 745 W, 6370 W=8.55hp ; 9hp = 6705W
Torque:
T = P/2πω = 6705/2π (1500) = 31.5 Nm
2.4 Design of System
Ladder logic allows us to control door openings, travel
direction, and time. Call buttons will move the car.
Elevator motion affects the amount of power and time
used. Motive is finding an efficient design and logic.
STEP 7 can be used to programme SIMATIC S7-1500 and
S7-300 Controllers and configure SIMATIC HMI Basic
Panels. This functionality allows STEP 7 to do both. TIA
Portal gives you unrestricted access to digitized
automation services, from planning to engineering to
operation. Siemens' SIMATIC WinCC is a simulation
software for SCADA and HMI systems. STEP 7 can be used
to programme SIMATIC S7-1500 and S7-300 Controllers
and configure SIMATIC HMI Basic Panels.

Fig. 5 Upward Movement Logic
Fig. 6 Downward Movement Logic
Fig. 7 Direction Assignment Logic
Fig. 8 Stopping Elevator Logic

Fig. 9 Open, Obstacle and Overload Logic
Fig. 10 Reset Open Door and Closing Door Logic
2.5 Working of the Simulation
The first floor marks the beginning of the operation for the
car. It makes no difference to the programme if the
elevator is located on a different floor. The car is started
by push buttons. It moves in an order that maximises the
amount of power saved, so if the car is moving in one
direction and another call comes in, it will respond to all of
the calls in the first direction before it responds to any
calls in the second direction. When the call signal and the
floor sensor are a match, the elevator will hang up the
phone. When the signal from the level sensor on the
second floor is high, a floor call is placed. Every call signal
on the second floor has been turned back to 0 now. After
having been opened for a predetermined amount of time,
the door is then closed in preparation for moving to the
next level. When the door is shut, the car is able to move
forward once more. If the door is closing, pressing the
Open button will reopen it, and if it is already open, it will
reset the amount of time it has been open. When the
passenger door is shut, the vehicle remains stationary
until it receives a signal from the Open button. In the event
that there is a barrier or that the elevator is too full, the
door will either remain open or reopen. An HMI screen
will display all of the operations when you are simulating.
The operation is the same in its entirety, with the
exception of a PLC and switches (Buttons). When
modelling, researchers need to take into account a variety
of factors that have the potential to affect elevator motion
and put customers in harm's way. In order to determine
whether or not the elevator is moving, fluctuating elevator
speed, and steady elevator slowing, the creation of the
model ought to centre on environmental analysis.
3. RESULT AND DISCUSSION
Following the completion of the error checking and the
interfacing of the PLC with the elevator, the trials of the
setup were carried out, and it was found that the setup
functioned correctly. The operation begins with pressing
the button for the desired flow, and if the elevator is
already on that floor, the motor will start running
according to it; for example, if the elevator is located
below the desired floor, it will rotate in a clockwise
direction, but if it is located above the desired floor, it will
rotate in a counter clockwise direction. There is a
significant amount of room for advancement in this
simulation, for instance. incorporating a weight sensor
into the lift in order to establish a maximum permissible
load for the lift to carry. Also, adding weight sensors to
each floor so that you can keep track of which floor has the
most people on it, or employing a weight counterbalancing
technique, should be done in order to make it
operationally feasible and for additional safety measures
like sounding the alarm when the weight of the lift reaches
the predetermined maximum level or when the door is
unable to close due to some obstacles, respectively. When
there are only a few stories in a building, this is one of the
most efficient and cost-effective ways to implement an
elevator. It is also possible to implement this using other
Softwares, some of which have more features and are
more compatible with one another that can drastically
optimize the modelling in real time scenarios.

Fig. 11 Live Simulation in TIA Portal
Fig. 12 Working Interface with HMI
4. CONCLUSION
Simulation ran successfully. Logic inputs and outputs for
elevator forward and reverse motoring, door opening and
closing motor operation, and other sensors on each floor
have been added, and the programme is evaluated and
simulated using Graphic Interface. Simulations of logic
have been created. The smaller size of wireless solutions
makes changes easier and faster. Diagnostics which are
centralized and overrides are built into PLCs.
REFERENCES
[1] Gupta, Shrey. (2015). PLC based Multi-Floor Elevator
Control System. IAES International Journal of Robotics
and Automation (IJRA). 4. 202.
10.11591/ijra.v4i3.pp202-208.
[2] Deepthi L R, Divya Dharshini J N, et.al (2021), Design
and Implementation of Three Floor Lift Using PLC.
International Conference on Advances in Materials,
Computing and Communication Technologies
(IJSRST), Vol 9 Issue 1, April 2021, ISSN 2395-6011.
[3] Ali, Mohammed. (2018). Design and Implementation
of an Electrical Lift Controlled using PLC. International
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[4] Han, Xiaohu. (2020). Design and research of elevator
control systems based on PLC. Journal of Physics:
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BIOGRAPHIES
Ajith Srikanth
Student, B. Tech Mechatronics
SRM Institute of Science and
Technology
https://www.linkedin.com/in/as31/
Nehaa V
Student B. Tech Mechatronics
SRM Institute of Science and
Technology
https://www.linkedin.com/in/vn07/

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