The design and simulation of an automated material sorting system using Siemens S7-1200 PLC integrated with Factory I/O and an HMI interface. It utilizes a combination of diffusion, vision and retroreflective sensors along with a pick-and-place mechanism to sort materials based on colour and stack them efficiently. A counter system is implemented to shut down the conveyor if more than 10 materials are processed, preventing potential damages. It is programmed using ladder logic and is entirely simulated within a virtual environment to enhance safety, precision, and operational efficiency in industrial automation. It integrates with the HMI and allows real-time monitoring and data visualization, providing operators with insights into the sorting process, sensor statuses, and conveyor operation. The use of a vision sensor ensures accurate color detection, while diffusion and retroreflective sensors enhance object positioning and detection precision. The pick-and-place mechanism, controlled by ladder logic in the PLC, ensures that materials are stacked correctly, contributing to efficient production workflows. By simulating the entire process in Factory I/O, the system provides a safe testing environment that mimics real- world manufacturing scenarios, allowing for further scalability and refinement before physical deployment.

The project focuses on developing an automated system to crush jaggery into powder form. The system employs a mobile-controlled rover using an ESP8266 module and the Blynk app, allowing for remote control via Wi-Fi. Temperature is continuously monitored by a thermocouple connected to a MAX6675 module, which provides digital input. When the temperature drops below 120°C, a DC motor with an attached blade is activated by an L293D motor driver, and a buzzer sounds for 5 seconds to alert the operator. This mechanism ensures timely intervention to prevent potential damage to the jaggery. In addition, the system monitors the humidity of the caramelized jaggery. If the humidity level reaches 60%, indicating that the process should be stopped, the buzzer is triggered as an alert. The integration of mobile control, temperature sensing, and humidity monitoring creates an efficient, user-friendly system for automating the jaggery powder crushing process. Utilizing commonly available components and wireless communication technology, the proposed solution is cost-effective and scalable, making it ideal for small to medium-scale jaggery production facilities.

The paper presents an automating oil pressure safety control and consistency control through the integration of Node MCU represents a pivotal advancement in the domain of oil extraction processes. This innovative approach leverages cutting-edge technology to enhance operational efficiency, mitigate potential hazards, and ensure consistent product quality. By employing Node MCU's in this project the operators can swiftly detect deviations or anomalies, triggering immediate responses to prevent accidents and equipment breakdowns. By dynamically adjusting variables such as pressure, temperature, and extraction duration, Node MCU facilitates the production of high-quality oil products that meet stringent industry standards and consumer expectations. Overall, the integration of Node MCU for oil pressure safety control and consistency control heralds a transformative evolution in the industry.

Textile calendaring is an important process for improving fabric quality. This is achieved by passing the cloth through hot rollers placed under high tension. The process smooths the texture and regulates the shrinkage to achieve superior fabric quality. This project proposes integrating a Variable Frequency Drive (VFD) to introduce a dynamic procedure for roller speed control that accommodates diverse cloth characteristics. The study varies the speed of the rollers based on the cloth material inserted. By harnessing advanced technology, our study aims to revolutionize textile manufacturing practices and set new standards for quality and excellence in end products.

The Siemens PLC in combination with Factory I/O to automate palletizer and storage systems is a modern method that improves efficiency in handling, stacking, and storing goods in industrial and storage environments. This setup links Siemens PLCs with Factory I/O, a 3D industrial simulation software, to automate the transfer of items from assembly lines to pallets, arrange them in specific patterns, and place them in designated positions. Automation reduces the need for human interaction, decreases errors, and enhances efficiency through faster palletizing cycles and maximizing storage space. Siemens PLC ensures accurate stacking and minimizes errors like incorrect pallet configurations. Factory I/O is crucial for simulating the entire process, allowing for fast problem detection, and reducing downtime. The system can quickly adjust to different product sizes and pallet configurations, and the efficient tracking of palletized items maximizes warehouse space usage. Furthermore, automated monitoring reduces errors and speeds up product retrieval, improving overall material flow efficiency. This project demonstrates how automation improves efficiency, accuracy, and cost-effectiveness in industrial palletizing and storage operations.

Programmable Logic Controller (PLC) and Internet of Things (IoT) are two different emerging fields which are jointly used to communicate over distributed devices over internet. This provides an added advantage of automation and control with an ease operation and speedy network. A 6V DC input is given to stepper motor STM 981 which is connected to the conveyer belt for its movement. Once the material is sensed by the proximity sensor, then the conveyer belt gets stopped whereas the robotic arm picks the material from the conveyer belt and places it in the required site. The output signal from the robotic arm will be given to the PLC namely Siemens S7 1200 and further it is connected to 24 port-switches. Also, personal computer, IoT 2040 Gateway and Human Machine Interface (HMI) will be connected to the switch. Totally Integrated Automation (TIA) is a portal used to write ladder logic programming for PLC. For communicating PLC with IoT2040 gateway, python code will be written in software called MobaXterm. Also, python program is written in the same software for communicating IoT2040 gateway with Cloud and Cloud with PLC through IoT2040. The whole system is controlled through an online IoT platform called Ubidots, which provides a secure way to build IoT solutions.

This innovative "IoT-Based Bottle Filling System using Programmable Logic Controller (PLC)" is made to automate and improve bottle filling operations' efficiency. It is the main process of filling liquid products. Today, programmable logic controllers (computers designed for industrial control) are used to automate the water injection process. However, to start and finish this process, we need to manually monitor the factory operation. In this model, the filling of bottles is controlled by a controller called PLC and monitored via the Internet of Things. First, water is pumped through a motor and controlled by high and low water sensors on the treatment tank. Bottles are placed on the conveyor belt for the filling process. When the inductive proximity sensor detects the product and the position sensor shows the location of the bottle, the conveyor stops and the amount of water that should enter the bottle from the purification tank begins to pour. The signal output from the workstation is fed to the programmable logic controller (PLC), Siemens S7-1200, and continues through a 24-port switch. PCs, IoT 2040 gateways and human machine interfaces (HMIs) will also be connected to the switch. Totally Integrated Automation (TIA) is a portal to PLC ladder logic programming. In order for the PLC to communicate with the IoT2040 gateway, Python code will be written in a software called MobaXterm. Additionally, Python programs for communication between the IoT2040 gate and the cloud and between the cloud and the PLC were written in the same software. The entire system is managed by an online IoT platform called Ubidots, which provides a secure way to build IoT solutions.

Managing the liquid level of a spherical tank can be a challenging task due to the unevenness of its surface, which varies with the tank's height. Keeping the liquid level within the optimal range is crucial for maintaining optimal operation and ensuring high product quality. Due to the PID controller's simplicity, reliability, and precision in industrial feedback control loops, it cannot be used to operate complicated systems for best performance. Using PLC and, the level control system for spherical tanks is implemented in real time. Using the approach of process reaction curves, models of the various areas' responses are simulated. In simulation, the PID controller-based level control system settles on 1400 ms, 2950 ms, and 7725 ms for region-1, region-2, and region-3, respectively. Using the web application ubidots, LoRa and PLC controller experiments are conducted in real-time. The tank level control set point is transmitted via the web tool, and the PLC executes the control operation. The level control faceplate is used to monitor the different areas' level control systems.

The controller's primary responsibility in the process industry is eliminating numerous disruptions and maintaining stability. Like any process tank, the shape is crucial in the design of regulators. To lessen land and water pollution, wastewater treatment facilities are becoming increasingly common in many industrial and organizational sectors. Conical tanks are crucial components of sewage treatment facilities. In wastewater applications where the tank must be empty, cone bottom tanks are utilized to stop sludge from the tank from getting into the subsequent operations. Conical tanks are used in the process sector because it is simple to empty their contents. Controlling the level of liquid is an essential responsibility in many operations. In this research, the liquid level is managed in a conical tank system without interactions. Level control is incredibly challenging for conical tanks because of their non-linear features and wide range of size and diameter. Current methodologies incorporate Proportional-Integral-Derivative (PID) controllers in their control systems. 90% of automated controllers used in the process sector are PID controllers, the foundation for many sophisticated control algorithms and techniques. PID controllers are the industry standard for feedback control, and are commonly used in linear systems because of their simplicity, versatility, and effectiveness. However, the presence of non-linearities in the process can limit their applicability. This study describes the maintaining process levels at specified operating conditions and achieving optimal performance using a fuzzy-tuned PID controller.

Breast cancer is the second leading cause of cancer among women glob-ally. Several treatments are involved in breast cancer like surgery, chemother-apy, radiotherapy, and hormone therapy; chemotherapy being used most often. Multicellular systems complications can be deeply understood by analyzing and studying how cells grow, move, divide, die and interact. To examine these fac-tors, we use PhysiCell as our modelling platform. Virtual cell growth analysis is essential to view the cancer cell growth daily. PhysiCell physics-based mul-ticellular simulator is an open-source agent-based simulator used to design a virtual model to analyze the changing cell cycle progression, volume, death, motility, mechanics and processes. Analysis was made on the cancer cell death rate, cell damage rate, and cell repair rate. Data were taken for every 6 hours of simulation and the result confirms that the chemotherapeutic agent kills 45% of cancer cells.

Breast cancer is the second leading cause of cancer among women globally. Several treatments are involved in breast cancer like surgery, chemotherapy, radiotherapy, and hormone therapy; chemotherapy being used most often. Multicellular systems complications can be deeply understood by analyzing and studying how cells grow, move, divide, die and interact. To examine these factors, we use PhysiCell as our modelling platform. Virtual cell growth analysis is essential to view the cancer cell growth daily. PhysiCell physics-based multicellular simulator is an open-source agent-based simulator used to design a virtual model to analyze the changing cell cycle progression, volume, death, motility, mechanics and processes. Analysis was made on the cancer cell death rate, cell damage rate, and cell repair rate. Data were taken for every 6 hours of simulation and the result confirms that the chemotherapeutic agent kills 45% of cancer cells.

The present scenario in the electrical department is to improve energy proficiency and to investigate innovative compelling and increasingly smart approaches to use power consumption in industrial applications. Electrical machines are a basic requirement for operating various functions in the industry like a crane, blower, material handling systems, pharmaceutical industries and cement industries, etc. The three-phase Induction Motors (IM) is the prime wellspring of vitality employment in industrial applications. The utilization of the Variable Frequency Drives for the industrial application from a small range of induction motor into large capacity of induction motor ranges to improving the effectiveness and efficiency of the process output. The speed and position control is a combined module of the Variable frequency drive section and a Programmable Logic Controller (PLC). So joining the VFD drive with the PLC controller brings out the effective outcome of controller efficiency. The V20 drive having a module of single-phase to three-phase inverter circuit connecting with induction motor to approach of innovation and accessibility of movement control of electric motor with conveyor model, the use of Programmable Logic Controllers with power hardware in electrical machines developed and tested in the assembling hardware setup. In this hardware setup PLC with a VFD system for changing the position and speed more accurately of the drive system with load arrangements. The speed changing is proportionally generated by the PLC controller output signal. The speed control and position control of PLC based V20 drive module developed and tested successfully.

This paper describes the comparative study of Proportional Integral (PI) and Backstepping controller for Buck converter with R-load and DC motor. Backstepping approach is an efficient control design procedure for both regulation and tracking problems. This approach is based upon a systematic procedure which guarantees global regulation and tracking. The proposed control scheme is to stabilize the output (voltage or speed) and tracking error to converge zero asymptotically. Buck converter system is simulated in MATLAB, using state reconstruction techniques. Simulation results of buck converter with R-load and PMDC motor reveals that, settling time of Backstepping controller is less than PI controller.