S.T. Sanamdikar et al.

/ IJAIR ISSN: 2278-7844

2012 IJAIR. ALL RIGHTS RESERVED
131

AUTOMATION IN POLYHOUSE USING
PLC
S.T.Sanamdikar#, V.G.Suryawanshi*S.S.Shete#
Instrumentation& Control Dept. PDEAs, COEM, Pune.INDIA
sanamdikar@yahoo.com
Abstract : Agriculture is the backbone of our country. The available management is not sufficient to that of requirement.
Today the farmer themselves manages all the things which crop requires, but every person do not have the exact knowledge of
the quantity and the time to apply to the crop. So here we have developed the system that will manage the temperature, humidity
and intensity for the crop one year using the Programmable logic controller (PLC). Every seeds manufacturing company as well
as regional agricultural colleges provide the yearly scheduled for the crop. Our system will take this as the input through the
program and then it will maintain temperature, humidity and intensity of polyhouse.
We can achieve desire results with the help of PLC. Using PLC we want to develop an automated continuous process
system for maintaining the house. Though the process seems to be simple but degree of automation is higher for proper operation
of a system. In this paper, we are discussing how we are going to develop this system, what is the basic theme of this project and
how our ideas will be applicable to the theme. We have designed a control system. We are detailing areas which are more
important to instrumentation and control engineer. The purpose of the project is to grow a crop in any climatic conditions at any
time. Proper design, selection, construction and management of the polyhouse and upgrading, construction of polyhouse using
sensors will give effect to house.


I. INTRODUCTION:-
At this point in time, the worlds pollution problem
has led to unpredictable weather conditions all over
the world. With these ever changing weather
conditions, it is expected that the number of
polyhouses will significantly increase in the near
future, thus leading to a great demand for automated
polyhouse monitoring systems .The main goal is to
build a miniature polyhouse which is equipped with
an automatic monitoring system. This monitoring
system will constantly monitor the conditions in the
polyhouse to ensure that it remains at preset
temperature, light humidity conditions.
If these conditions differ from the preset levels, the
monitoring system will automatically turn on certain
devices to return the polyhouse to the required
conditions.
Automatically control the crop growing environment
within the walls so that any type of plants can be
grown all year round. Eliminates the risk of the
polyhouse not being kept at crop specified conditions
due to human error. Minimizes the labor costs crop
involved in maintaining a playhouse. Customer will
be able to define their crop preferred polyhouse
conditions and have the system function as specified.
This will be a plug-and play product..
Detect temperatures from -40C to 125C. Maintain
a temperature of about 10C to about 40C. Detect
humidity between 5% RH and 95% RH. Maintain a
humidity of about 40% to 80% RH. Detect sunlight
and artificial light. Turn on artificial lighting in the
event that there is insufficient light.
1.1 Overall design:-
For our Automated Polyhouse Monitoring System,
we are implement 3 types of sensors. The sensors to
be used are photodiodes, a temperature sensor and a
humidity sensor. We are building a miniature
polyhouse and determine the appropriate positions to
place the sensors. A series of tests will be done to
make sure that all the sensors are working
accordingly. These sensors will be connected to a
PLC which will function as the main control unit.
The sensors will send signals to the plc and the plc
will translate the signals and determine if the input is
within the preset range. For instance, if the preset
temperature range is from 20C to 25C, the plc will
make sure that the polyhouse temperature is within
S.T. Sanamdikar et al. / IJAIR ISSN: 2278-7844

2012 IJAIR. ALL RIGHTS RESERVED
132

this range. If the temperature exceeds the maximum
value, the plc will then turn on the fan. If the
temperature drops below the minimum value, the
bulb will turn on. As for the photodiode, if the
polyhouse is exposed to insufficient light, it will send
a signal to the plc. The plc will then process the
signal and turn on the artificial light in the polyhouse.
As for the humidity sensor, it will detect a change in
humidity levels of soil and send a signal to the plc. If
the humidity level is not within the required range,
the water supply will be turned on or off. The plc will
be the central processing unit which will translate the
input signals from the sensors and turn on or off the
necessary devices to maintain the polyhouse at the
preset levels.
To maintain environmental conditions inside the
house for better production of crop with the help of
PLC which make it suitable for productive uses and
help improve crop quality and quantity.
II FORMULATION OF PROBLEM:
Agriculture has a vital role in our economy.
About 40 to 50 percent of our population depends on
the agriculture and its related field for their survivor.
The available management is not sufficient to that of
requirement. In manual system there is wastage of
water & fertilizers provided to the crop. In manual
system there is damage to crop because of heavy rain
or high temperature. The manpower required is more.
The process is time consuming. Maintenance is
required.
Thus we have developed the system that will
manage the temperature, humidity and intensity for
the crop with less manpower using Programmable
logic controller.
III SYSTEM IMPLEMENTATION:
The block diagram of Automation in polyhouse
using PLC is shown in figure (III.1). Details of each
block are given below.
a) BLOCK DI AGRAM DESCRI PTI ON:
1. Programmable Logic Controller:
We will use PLC uses 24V dc power supply.
Actual programming is stored in the PLC.
2. Humidity:
We will use humidity sensor for sensing the
humidity of soil. After that this signal is
send to plc. In that plc a particular set point
is given and if it is below or above it take
action likewise.
3. Temperature:
We will use thermocouple as temperature
sensor. Temperature is sense an after that
this signal is send to plc. In that plc a
particular set point is given and if it is below
or above it take action likewise.
4. I ntensity:
Intensity will be sense by photodiode. If
intensity of sun increases then green net is
used for reducing the intensity using plc.
5. Cooling Pad
The cross fluted cellulose pad is
preferred. These are available mostly in
100mm thickness. One meter of pad height
is given for every 20m of pad to fan
distance. However, the fan to pad distance
should not exceed 60m.The air flow rate
should be of 75 cubic meter/minute/sq.m of
pad. The water flow rate should be of 9 liters
per minute/linear meter pad. The uniform
distribution of water on pad is to be
maintained.

6. Exhaust Fan:
The fans should deliver the required air
at 15mm static pressure. The maximum
center to center spacing between the two
fans should be of 7.5m. The height of the
fans is to be determined based on the plant
height which is proposed to be grown in the
greenhouse. The fan blades and frame are to
be made of non-corrosive materials like
aluminum/stainless steel.

7. Relative humidity control:
The humidistat coupled to water
circulating pump to control the relative
humidity of soil. Here we maintain the
relative humidity of soil. This is one type of
watering system in this soil sensor is use to
find out humidity in soil and if it is less then
motor pump start and water is giving to the
soil.
8. Light intensity control:
In certain areas where natural
illumination is absent or very low,
illumination for plants may be provided by
artificial sources. Incandescent bulbs
generate excessive heat and are
unsatisfactory in most instances. Fluorescent
tubes are useful as the sole source of light
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133

for African violets, gloxinias and many
foliage plants which grow satisfactorily at
low light intensities. Excessive light
intensity destroys chlorophyll even though
the synthesis of this green pigment in many
plants is dependent upon light.
Chrysanthemum is a classic example for a
short-day plant. However, flower buds will
not form unless the night temperature is high
enough. Chrysanthemum is flowered on a
year-round basis as a cut flower or potted
plant simply by controlling the length of day
and temperature.

IV: SOFTWARE DESIGN:
This chapter is basically gives the details of
software. The main software is PLC and in this
chapter it gives the details of which PLC is use and
the ladder diagram
a) Flow chart: flow chart of above system as shown
in figure IV-1.
b) Programming Logic Controller :
Control engineering has evolved over
time. In the past humans were the main methods for
controlling a system. More recently electricity has
been used for control and early electrical control was
based on relays. These relays allow power to be
switched on and off without a mechanical switch. It
is common to use relays to make simple logical
control decisions. The development of low cost
computer has brought the most recent revolution, the
Programmable Logic Controller (PLC). The advent
of the PLC began in the 1970s, and has become the
most common choice for manufacturing controls.
PLCs have been gaining popularity on the factory
floor and will probably remain predominant for some
time to come. Most of this is because of the
advantages they offer.
Now why only PLC? We use PLC
because it is capable of handling large no of inputs
without need of human interfacing. Once it is
correctly programmed the operator doesnt have to
bother about the process.
Cost effective for controlling complex systems.
Flexible and can be reapplied to control other
systems quickly and easily.
Computational abilities allow more sophisticated
control.
Trouble shooting aids make programming easier
and reduce downtime.
c) Manufacturers of PLC:-Allen
radley.Siemens.Mitsubishi.Honeywell.Fanuc.Toshi
ba.Anshuman. In our system the PLC program is
going to control the valve i.e. is amount of acid or
base is to be adding into treated water. It also controls
the positions of all the levels of the different tanks in
the process. This will help to control the system
smoothly.
IV.2 Basic Elements of PLC:
PLC mainly consists of a CPU, memory areas and
appropriate circuits to receive input/output data. We
actually consider the PLC to be a box full hundreds
and thousands of relays, counters, timers and data
storage locations. They dont physically exist but
rather they are simulated and can be considered as
software counters, timers, etc. Each components of
PLC has specific function.
I nput relays (contacts):- These are connected to
outside world. They physically exist and receive
signals from switches, sensors, etc. Typically
they are not relays but rather they are transistor.
I nternal Utility Relay:- These do not receive
signals from outside world nor do they
physically exist. They are simulated relays and
enables PLC to eliminate external relays. There
are also some special relays that are dedicated to
perform only one task. Some are always on
while some are always off. Some are on only
once during power-on and typically used for
initializing data that was stored.
Counters:- These are simulated counters and
they can be programmed to count pulses.
Typically these counters can count up, down or
both. Since they are simulated they are limited to
their speed. Some manufactures also includes
high speed counters that are hardware based. We
can think it as a physical existence.
Timers:-These come in many varieties and
increments. Most common type is on-delay type.
Others includes off delay and both retentive and
non retentive type. Increment varies from
1milliseconds to 1 second.
Output relays:-These are connected to outside
world. They physically exist and send on or off
signals to solenoids, lights, etc. They can be
transistors or relays depending upon their model.
Data storage:- Typically there are resisters
assigned simply to store data. They are usually
used for temporary storage for math or data
manipulation. They can also be used to store data
when power is removed from the PLC
Languages in PLC:
1. Ladder DiagramFunctional Block
Diagram.Structural text .Instruction List
2. Sequential functional chart
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Ladder Diagram:
The ladder diagram has and continues
to be the traditional way of representing electrical
sequences of operations. These diagrams represent
the interconnection of field devices in such a way that
the activation or turning ON, of one device will turn
ON another device according to a predetermined
sequence of events. Figure IV-2 illustrates a simple
electrical ladder diagram. The original ladder
diagrams were established to represent hardwired
logic circuits used to control machines or equipment.
V Testing and Result analysis:
a. Testing of solenoid valve:-
All solenoid valves were tested and verified
by giving them a supply of 24V and a pressure of
1.2Kg/cm2. It was verified that all of them open
when a supply of 24V was given to them. Specific
problem encountered during valve testing was that
diaphragm one of the solenoid valve was damage
which needed replacement.
b. Testing of switches:-
All switches were tested by giving them 24V supply.
All of them have been working fine
c. Testing of Transmitter:-
Transmitter was tested by giving 24V supply. It has
been working fine
d. Testing of Agitator and conveyor motor:-
A motor 24V DC supply is given to
agitator and conveyor motor in order to test it. The
agitator available in the lab has been working nicely
without any error.
e. Testing of pump and automating it:-
The pump had to be tested for its working
and efficiency. We also needed to automate the
pump. The pump is automated by connecting a relay
of 24V to 230V so that once you connect the pump
wiring to the relay, the pump starts as soon as a 24V
signal is given to it by the PLC.
f. Testing of process wiring and troubleshooting it:-
The crux of all troubleshooting was testing
of through process wiring. The entire system had to
be connected to the PLC. In numerable problems
were encountered in this process specially like. Wire
not been connected to the proper port. Wires all
connected at wrong points either on the junction box
and terminal strips. Few instruments were not
connected to the PLC.

V.2 Results:
In this way we maintain the environment of
polyhouse using PLC and sensors.
In this way after taking lots of efforts we are
successful to make automated Polyhouse. PLC
have some Digital as well as some Analog input
after sensing them it will take the decision as per
ladder logic and handle number of digital outputs
for polyhouse.
Due to automation there is no necessity of
number of worker to handle farm. Only one trend
person will easily handle the polyhouse.

VI: Conclusion:
In this paper we can say that automation in
polyhouse is not easy as it seems. It has great
importance in farm as well as in society. During this
project we realize that environment control processes
are very precise and well controlled. Using PLC
techniques we can automate the whole polyhouse. As
we see crop is one of the important parts of all of us
and to increase the crop polyhouse is best option. In
this way we will make automated polyhouse using
plc. And we provide farmers a new world of
technology. Because of this project farmer will
become rich and everyone who think that farming is
from village people or illiterate people they will also
do farming and improving this system.
REFERENCES
1. Clarence A. Phipps, Fundamentals of electrical control,
Publisher The Fairmont Press, Inc., 1999, Edition2, illustrated,
213, Page no.162,164,165.
2. Ramakant A. Gayakwad, Op-Amps and Linear Integrated
Circuits, Publisher PHI prentice hall India, Fourth Edition, 543,
Page no.438,439
3. Gary Dunning, Introduction to Programmable Logic
Controllers, Edition third, 628 .
4.Agricultural Statistics at a Glance (2008), Department of
Agriculture and Cooperation, Ministry of Agriculture, Government
of India.
5. A. Rokade, Assistance and Control System for Polyhouse
Plantation, M. Des. Thesis, IDC IIT Bombay (2004).
6. T. Ahonen, R. Virrankoski, M. Elmusrati, Greenhouse
Monitoring with Wireless Sensor Network, IEEE / ASME
International Conference on Mechatronic and Embedded Systems
and Applications, pp. 403-408, 2008
7A. Joshi, N. Madame, System for Polyhouse Farmers and
Consultants, 3rd India International HCI Conference, USID
Foundation, 2009, Hyderabad, India.
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135

INPUT SIDE OUTPUT SIDE








Figure III.1 Block diagram of the system



Figure IV.3: Basic elements of PLC


Temperature
sensor
PROGRAMMABLE
LOGIC CONTROLLER
Humidity sensor
(soil)

Intensity
Sensor
Exhaust fan
Motor pump for feeding water
Bulb for increase temperature
Dc motor for opening and closing of
green net
POWER SUPPLY
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Figure IV.1 FLOW CHART


S.T. Sanamdikar et al. / IJAIR ISSN: 2278-7844

2012 IJAIR. ALL RIGHTS RESERVED
137


Figure: IV-2Ladder Diagram