A sequential control system for a chemical mixing station using a Delta PLC and Ladder logic, with level sensors, temperature monitoring and a DOPSoft HMI, tested in simulation.
An academic project carried out by a team of students with technical assistance from Techno Enjaz to design an automated control system for a chemical liquid mixing station based on a Delta Programmable Logic Controller (PLC). The system transfers two materials (A and B) from two feed tanks into a main mixing tank using sequential control driven by level sensor readings, then runs the mixer motor once filling is complete, while monitoring the mixture temperature.
The project was implemented in a simulation environment: Ladder Diagram programming for a Delta DVP-ES2 PLC in ISPSoft, an operation and monitoring HMI designed in DOPSoft, and the two linked through Delta's software emulator and COM Manager. The simulation showed the operating sequence working: safe start and stop, sequential pump control, liquid transfer, mixer start after filling, and temperature monitoring on an animated graphical interface.
| Item | Details |
|---|---|
| Project type | Automated control system for an industrial process (liquid mixing automation) |
| Field | Industrial automation, PLC programming, HMI monitoring |
| Project status | Programmed system tested in a software simulation environment |
| Techno Enjaz role | Technical support and assistance to the students during project development |
| Core technologies | Delta DVP-ES2, Ladder Diagram, ISPSoft, Delta WPLSoft, DOPSoft, Delta Emulator, COM Manager |
| Outputs | Sequential control program, interactive HMI, full simulation of the fill and mix cycle |
Many conventional chemical mixing systems still rely partly on manual operation or limited control systems, which leads to:
Temperature monitoring matters all the more because temperature is a critical factor in many chemical reactions, and exceeding its limits can create serious operational risks. This led to the idea of a PLC system that runs mixing in a safe logical sequence with continuous monitoring.
The project was carried out academically by the students, with technical assistance and support from Techno Enjaz during development. It is presented among the office's work as an example of its support for industrial automation projects, PLC programming, and HMI interfaces.
| Component | Role in the system |
|---|---|
| Delta DVP-ES2 PLC | Executes the sequential control logic |
| Two feed tanks and the main tank | Store materials A and B, then receive the mixture |
| Sensors S1, S2, and S3 | Confirm that liquids are present and at safe operating levels before the pumps start; wired to digital inputs |
| Two pumps (outputs Y0 and Y1) | Pump liquids from the feed tanks to the mixing tank |
| Mixer motor | Mixes the liquids in the main tank once filling is complete |
| Temperature indicator | Tracks the state of the mixture during operation |
| Start, Stop, and Emergency buttons | Start, stop, and emergency shutdown |
The control program was developed in ISPSoft using Ladder Diagram and divided into several logic networks:
The project summary refers to programming in Delta WPLSoft, while the implementation chapter developed the program in ISPSoft; both are Delta tools for the DVP series.
The interface was designed in DOPSoft and shows the liquid tanks, the pumps, the main mixing tank, the start and stop buttons, the sensors, and a temperature indicator. It animates the state of the pumps, the flow of liquid through the pipes, and the mixer motor, with the mixer impeller changing color when mixing starts.
The system was tested without physical hardware, using Delta's software emulator. COM Manager was used to connect ISPSoft with DOPSoft over the local address (localhost) using Delta protocols, allowing real-time data exchange between the virtual PLC and the HMI during simulation.
The simulation showed the system successfully performing the following functions:
These are functional simulation results; the project reports no timing measurements and no tests on real hardware or actual liquids.
According to the directions set out in the project, the system could be developed by:
If you are working on a PLC-based control system or industrial process automation and need technical help developing the idea or building a prototype, you can contact the Techno Enjaz office to discuss your project's requirements and the appropriate scope of support.
It is an automated control system designed by a team of students with technical assistance from Techno Enjaz. It transfers two materials from feed tanks into a main mixing tank in a logical sequence driven by level sensors, then runs the mixer motor and monitors the mixture temperature. It was built for a Delta DVP-ES2 PLC and tested in a software simulation environment.
The program consists of Ladder networks: a start, stop, and emergency circuit that energizes internal relay M0; timer T0 that sequences the pumping; networks that run the two pumps through outputs Y0 and Y1 once sensors S1, S2, and S3 are satisfied; mixer start after filling with conditional compares for temperature monitoring; and MOV instructions that update the HMI.
The control program was developed in Ladder Diagram using Delta ISPSoft, and the project summary also refers to Delta WPLSoft. The HMI was designed in DOPSoft, and Delta's software emulator was used with COM Manager to link ISPSoft and DOPSoft over localhost for real-time data exchange.
The simulation showed the system starting and stopping safely, controlling the pumps in sequence, transferring liquids to the mixing tank, starting the mixer after filling, monitoring temperature, and displaying the process on an animated HMI. These are functional simulation results, without timing measurements or tests on real hardware.
The project was limited to simulation and does not cover large production lines, complex chemical reactions, or full SCADA and DCS systems. Proposed developments include adding SCADA, expanding the number of tanks, using more accurate analog sensors, and integrating Modbus TCP and Ethernet/IP for Industrial IoT connectivity.
Reach out to Techno Enjaz engineering team to discuss technical feasibility, prototype hardware, and development scope.
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