PLC-BASED SMALL-SCALE ELEVATOR SYSTEM: A

REALISTIC FUNCTIONAL MODEL

Dela Cruz, Michael Simon C, Kaindoy, John Clyde J, Pelostratos, Brian Ezer T, Pogoy, Johmel M, Solindom, John Mark G, Tan, John Paul
Bachelor of Science in Mechanical Engineering
Visayas State University
Baybay City, Philippines
[email protected], [email protected], [email protected], [email protected],
[email protected], [email protected]

I. INTRODUCTION III. STATEMENT OF THE PROBLEM

The rapid development of automation in our daily Elevators provide efficient and fast way to transport
lives has become a defining characteristic of modernization people from different floor levels. While elevators provide
and technological advancement. The Internet of Things solutions to these problems, the cost-effectiveness,
(IoT) is a key technology that reduces human effort and reliability, efficiency and the vision of improving these
provides numerous information for individuals. One of the systems continues to grow at a rapid rate. Traditional
innovations of this era is the Programmable Logic elevator systems require complex wiring, huge
Controller (PLC), a widely used device controller for maintenance fees, and numerous components which can
providing instructions and control to machines and result to time consuming diagnostics or troubleshooting
processes that require high precision. PLCs are beneficial and increased cost for its operational fees to maintain the
across various industries that rely on automation. They can system.
perform logic sequencing, timing, counting, and arithmetic, This project aims to fabricate an educational three-
minimizing the need for wiring, contactors, timers, and story trainer elevator that is integrated by the use of
counter devices. The PLC's integrated built-in memory, Programmable Logic Control (PLC) system. By taking
timers, counter devices, and programmable latching advantage of different functions of the PLC’s, it can
simplifies system design without compromising efficiency exponentially boost the performance of the system and
and reliability. This makes the PLC an asset across various minimizing the wiring complexity that a traditional
industries that rely on automation. elevator has.
The primary problem that people experience in a
high-rise building is that repetitive and nonstop use of
staircase leading to discomfort and inefficiencies in IV. OBJECTIVES
performing tasks. Navigating different floor can lead to
discomfort and exhaustion. As engineers, we see it as a This project aimed to fabricate an educational
problem that needs to be solved immediately. student friendly three-story elevator trainer that assess PLC
To address this issue, we propose the automation programming skills and capabilities and deepen the
using PLC based program to the elevator system of the knowledge on PLC. To realize more of this project, it
building. This solution showcases the advanced capabilities specifically aims to:
of PLC’s that will ensure smooth, precise and reliable
operation. The automation of the building’s elevator using 1) To design and fabricate desired elevator structure,
PLC will also enhance the experience of users by appearance, mechanisms, and circuit diagram.
eliminating the problems of using stairs providing comfort
and ease. 2) To install and integrate selected precise electronic
components and sensors necessary for the elevator trainer
II. ABSTRACT and
This project presents a realistic model of an elevator
3) To create a ladder diagram language in programming the
using PLC as its system. The integration of the PLC
PLC.
controller boosts the performance of the system
maximizing its efficiency while minimizing the complexity
of the individual wirings for each component of the three- V. SIGNIFICANCE OF THE STUDY
story elevator. Programmable Logic Control device is used
High-rise buildings often experience discomfort and
to perform logical sequencing and time delay of the
inefficiencies due to repetitive staircase use, leading to
elevator. Different electronic materials, wires, and sensors
exhaustion and fatigue. Engineers propose an automation
were added to make the three-story elevator functional. The
solution using a PLC-based program to improve the
elevator model is developed and executed according to the elevator system. This solution showcases advanced PLC
plan demonstrating its full functionality that aligns with the
capabilities, ensuring smooth, precise, and reliable
design and integration of the PLC to the system.
operation. The automation of the building's elevator will
enhance user experience by eliminating stairs-related

MEng 125n – Basic Electronics

2nd Semester SY 2020-2021
Instructor: Engr. Philip Caesar L. Ebit
problems, providing comfort and ease. This solution is quickly adapt to changing market conditions and customer
crucial for addressing the primary problem faced by people requirements, and automation can improve employee
in high-rise buildings. safety by reducing the risk of accidents and injuries. This
The project mainly focuses only on mechanical, can lead to a safer work environment and reduce the
electrical/electronic aspects that an elevator has in order to organization's liability. PLC automation allows
function. It only uses Programmable Logic Control (PLC) organizations to collect and analyze data related to their
device to control the elevators operation such as timers and production processes. This can provide many benefits to
logic sequencing. The implementation of the functions is help organizations improve production efficiency, reduce
only on floor selections and door control. However, costs, and increase profitability.
aesthetics and beautification are not focused on the project
as it is only aimed to project the integration and of PLC
device to simulate an elevator system. Elevators using PLC
Elevators are essential components of contemporary
electronic control modules, especially those used in
building automation and automotive applications. Efficient
VI. REVIEW OF RELATED LITERATURE
and dependable elevator systems are now crucial in
PLC Control Based System emerging nations like Myanmar, where the number of high-
rise structures is growing quickly. This study focuses on the
The study introduces a monitoring and control
creation of a working elevator model and the use of a PLC
system for an induction motor using advanced
to control the elevator's circuits. Engineers' interest in
programmable logic controller (PLC) technology for
elevator control has been growing (Covington M.A., 2000).
electric machine automation. Factories use PLCs to Compared to the conventional relay controls utilized in
maximize efficiency and quality while lowering production many applications, such as automation and industrial
costs. The system integrates hardware and software
processes, controlling a mechanical system is simpler.
components for precise speed control and robust protection
Sensors are a natural choice in various industrial processes
mechanisms. The PLC plays a critical role in correlating
since they are simple to integrate with PLC. Caiqiao Wei
operational parameters to user-set speeds and continuously (2014) mentioned the wireless module as a transmission for
monitoring the motor's status. Performance evaluations the user information are being adopted by the use of PLC.
show superior speed regulation compared to traditional V/f
The control system of elevator are made with the use of
control systems. The PLC-based system achieves
PLC together with a wireless calling device and a wireless
significant efficiency improvements, particularly at
receiver.
elevated speeds, reaching up to 95% of the synchronous
The proposed system integrates a Hall Effect
speed. This study emphasizes the flexibility, accuracy, and sensor to accurately determine the elevator's position. A
reliability of PLCs as indispensable tools for industrial DC motor is employed to facilitate the vertical movement
applications, particularly in effective management and
of the elevator car, ensuring smooth and precise operation
control of electric drive systems. The supervisory control
in both upward and downward directions. User interaction
theory introduces an event-driven methodology aimed at
is enabled through push-button controls, which allow
optimizing the design and operation of industrial control
individuals to summon the elevator car. Additionally, the
systems using commercially available PLCs. current position of the elevator is visually indicated using a
display unit, enhancing usability and functionality.
PLC Efficiency The control logic for this system is implemented
using Auto Station Software, employing a ladder logic
The paper focuses on improving energy efficiency program designed to operate a four-floor elevator system.
(EE) in multi-hop cooperative communication systems, This study demonstrates the effectiveness of PLC
particularly power line communications (PLC). It proposes technology in developing practical and scalable solutions
a dual-hop amplify-and-forward (AF) cooperative relaying for building automation, contributing to the advancement
PLC system that incorporates energy-harvesting (EH) of infrastructure in regions experiencing rapid
capabilities at the relay node. The system uses an energy urbanization.
harvester to effectively forward source information due to
the high noisy PLC channel characteristics and transmitted
signal power. The study validates the findings through
Monte Carlo simulations and compares the performance of VII. METHODOLOGY AND DATA
a conventional relaying system without an EH mechanism. At the inception of the elevator trainer project, the
The results show that the proposed system offers design phase played a crucial role in virtually realizing our
substantial improvements in EE for PLC systems, and desired output. This phase allowed us to anticipate potential
increasing channel variance further enhances the energy challenges in fabrication and erection, accurately estimate
efficiency of the setup. and decide on the necessary materials for procurement,
PLC automation also improves the quality of determine the construction of the mechanism, and
products by reducing the risk of errors and inconsistency, systematically plan the Gantt chart to ensure completion
which can lead to increased customer satisfaction. within the desired timeframe. Following the design phase,
Automation can also be customized to meet the specific the Gantt chart was implemented to serve as a structured
needs of the organization. This can enable organizations to

MEng 125n – Basic Electronics

2nd Semester SY 2020-2021
Instructor: Engr. Philip Caesar L. Ebit
guide, outlining weekly tasks to be accomplished in BILL OF MATERIALS
adherence to the project timeline.
Subsequently, we proceeded with the online NAME OF PRICE
procurement of all required materials, including a
MATERIALS
customized PCB design for the circuit diagram of each DC
motor in our system. Concurrently, we developed and Arduino UNO R3 ₱150.00
tested our preliminary PLC code using a PLC trainer to Voltage Regulator ₱150.00
evaluate its functionality in accordance with real elevator Soldering Lead ₱130.00
mechanisms. This early-stage testing allowed us to identify Hookup Wire ₱82.00
and address critical conditions that required attention. The
Automotive Wire ₱860.00
next phase involved erecting the base and pillars of the
structure, utilizing alloy steel, and cutting acrylic glass for Bolts & Nuts ₱618.00
the frame and PLC wiring panel, ensuring alignment with Mechanical Relay ₱152.00
the initial design. Bulldog ₱345.00
Upon the arrival of materials, we conducted High Torque DC Motor ₱544.00
accuracy tests on the sensors and DC motors. As we
Shaft Coupler ₱118.00
progressed, we strategized the construction of our
mechanism and ultimately decided to integrate a Beyblade PCB ₱566.00
gear and guide system for the cabin door. This setup DC Motor & Voltage ₱1121.00
allowed the DC motor to drive the gear along the guide, Regulator
facilitating the opening and closing of the door. The same Angle Bracket ₱41.00
mechanism was applied to the external doors on each floor, Banana Sockets ₱76.00
ensuring synchronized operation with the cabin door upon
reaching the designated floor, thereby mimicking real-life Lamps ₱315.00
elevator behavior. Once the mechanism was established, Acrylic Glass & Laser ₱3387.00
we proceeded with the installation of sensors and the Cutting
routing of wiring across all components. Upon completing Drill Bit ₱110.00
the setup, we organized the wiring for efficient Wire 14 AWG ₱125.00
management. At this stage, we conducted trial runs and
Wood Glue ₱100.00
system testing, integrating the PLC code to maneuver the
elevator. Given the numerous conditions that needed to be Relay 5V ₱520.00
accounted for in the code to accurately simulate real-life Fare/Gas ₱200.00
elevator operations, multiple calibrations were performed Banana Plug Wire ₱209.00
to achieve optimal functionality. Banana Plug ₱1397.00
LED Strip ₱237.00
Toys ₱511.00
TOTAL: ₱ 12,064.00

PLC ELEVATOR FLOW CHART:

MEng 125n – Basic Electronics

2nd Semester SY 2020-2021
Instructor: Engr. Philip Caesar L. Ebit
 VIII. RESULT AND DISCUSSION
The elevator trainer project was successfully
developed and executed as planned, demonstrating full
functionality in accordance with our design and objectives.
Each stage of the project, from conceptualization to
implementation, was carefully structured to ensure a
smooth development process, with particular attention
given to design accuracy, material selection, mechanism
construction, and system integration.

Figure 7.3 Solidworks design for Control Panel

Figure 7.1 AutoCad Design of the project

Figure 7.4 Control Panel with buttons

Another challenge we encountered was controlling the DC

motor’s forward and reverse motion. Given that our system
was primarily electronics-based rather than a large-scale
industrial setup, we needed an alternative to conventional
contactors. Through research and experimentation, we
determined that using relays was an effective solution for
reversing the motor's direction, allowing us to achieve the
desired operation without requiring large-scale
components.

Figure 7.2 Front and perspective view

One of the key achievements was the effective

synchronization of the cabin and external doors, which
operated seamlessly using the Beyblade gear and guide
system. This mechanism, powered by DC motors,
accurately mimicked real-life elevator door movements,
ensuring that the doors opened and closed precisely when
the cabin reached the designated floor. However, perfecting
this door mechanism presented significant challenges since
we had to create a DIY solution due to the unavailability of
a 3D printer for customized parts. As a result, we Figure 7.5 Voltage Regulator
underwent numerous trial-and-error attempts to properly
install and optimize the mechanism, ensuring smooth
movement and proper alignment.

MEng 125n – Basic Electronics

2nd Semester SY 2020-2021
Instructor: Engr. Philip Caesar L. Ebit
 Structural components, including alloy steel pillars and an
acrylic glass frame, provided a stable and well-aligned
foundation for the entire system. The wiring and control
panel were systematically arranged, ensuring proper power
distribution and signal transmission across all components.

Figure 7.6 PCB Circuit board design

Figure 7.10 Elevator and Control panel wiring

During trial runs, the elevator trainer operated as intended,

successfully executing floor-to-floor movements, door
synchronization, and automated stopping sequences based
on programmed logic. Adjustments were made to further
optimize timing and sensor response, resulting in an
Figure 7.7 PCB Circuit Board accurate and responsive system.

The PLC code (Appendix, pp 20-24) implementation

played a critical role in automating the elevator’s functions.
Initial testing on a PLC trainer allowed us to refine the logic
and conditions necessary for smooth operation. Through
several calibrations, we ensured that the elevator responded
correctly to floor selections, door movements, and safety
interlocks, making the system both efficient and reliable.

Figure 7.11 Elevator Trainer Project

Figure 7.8 DC Motor Connection

Figure 7.9 Control Panel Connection

MEng 125n – Basic Electronics

2nd Semester SY 2020-2021
Instructor: Engr. Philip Caesar L. Ebit
IX. CONCLUSION AND RECOMMENDATION (PLC)," European Journal of Interdisciplinary
Research and Development, pp. pp.211-220, 2024.
While the project was successfully executed, certain [11] K. M. A. B. &. S. A. Rabie, "Improving energy
challenges could be addressed for future improvements: efficiency in dual-hop cooperative PLC relaying
Use a Pre-Designed or 3D-Printed Mechanism for systems," In 2016 International Symposium on Power
the Doors – Instead of relying on a DIY approach, Line Communications and its Applications (ISPLC),
pp. pp. 196-200, 2016, March.
fabricating a customized mechanism using a 3D printer or [12] L. L. &. W. H. Y. Wang, "Development of a distributed
CNC machining would enhance the precision, durability, control system for PLC-based applications," In 2010
and efficiency of the door operation. This would eliminate International Conference on Machine Learning and
the extensive trial-and-error process and ensure smoother Cybernetics, vol. Vol. 2, pp. pp. 906-909, 2010, July.
integration with the system. [13] M. G. Ioannides, "Design and implementation of PLC-
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Instead of manually wiring components, designing a IEEE transactions on energy conversion, pp. pp.469-
dedicated PCB for all system connections would improve 476, 2004.
circuit organization, reduce wiring complexity, and
enhance the overall reliability of the system. A PCB would
also make troubleshooting and future modifications more
efficient.
By applying these recommendations, future
iterations of the elevator trainer can achieve higher
efficiency, ease of assembly, and improved performance,
making it a more robust and scalable prototype.

X. REFERENCES

[1] S. R. P. S. A. &. S. V. K. Darshil, "Development of a

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[10] E. A. A. S. Altaiy, "ENHANCING EFFICIENCY
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PROGRAMMABLE LOGIC CONTROLLERS

MEng 125n – Basic Electronics

2nd Semester SY 2020-2021
Instructor: Engr. Philip Caesar L. Ebit