Development of a "Programmable Logic Controller Circuitry" For Optimal Power Distribution in a Manufacturing Industries

Problem statement: In industries the powder demand/consumption is fixed by the power supply agency. However, at times, the demand/Consumption may exceed the fixed level and will result in, the industry paying heavy penalties to the supply agency. In most of the large and medium scale industries, controlling of power consumption is done by monitoring the powder demand indicator unit activated by a microprocessor (μp) circuitry. The major drawback of controlling the consumption using μp circuitry is that the peak value is fixed and cannot be changed in proportion to the fluctuation in load. To address above issue an attempt is made in the present work, to replace the μp circuitry with a PLC circuitry which provides for flexibility, i.e., to change maximum demand level based on the fluctuations in the load through suitable programming in the PLC circuitry. Approach: A detailed literature review was made on the application and functioning of supply controls using μp circuitry along with the associated limitations. The application of PLC circuitry in the place of μp circuitry is reviewed. The methodology of the present research was presented. The experimental work was briefed. Results: The various results were listed and discussed. Major conclusions drawn, based on the present research was shown. Conclusion: The major contribution of the present study lies, in zeroing the frequency of the power consumption, crossing the fixed level, through the design and development of an optimal PLC circuitry resulting in a significant savings in the power consumption.