PLT 307/3PROGRAMMABLE LOGIC CONTROLLER (PLC APPLICATIONS)

Prepared by:

Muhammad Aizat Bin Abu Bakar

10 June 2020 (Wednesday)

2.30 – 3.30 PM

ONLINE

Outline

Introduction

PLC 5 STEP Applications

Application 1: Automatic Stacking Operation

Application 2: Packaging Line Control

Application 3: Conveyor Belt Motor Control

Application 4: Measuring the Life of Cutting Knife

Exercise 1

Exercise 2

Introduction

The programmable controlled-based control systemoffers wide variety of configurations and capabilities.

These range from the single machine or processcontrol to an entire industrial plant control andmonitoring system.

After the decision has been made to use aprogrammable controller in a control application, thedesign engineer must complete the system design.

International standard PLC Programming Language:-

Ladder Diagram (LD)

Function Block Diagram (FBD)

Instruction List (IL)

Sequential Function Chart (SFC)

Structure Text (ST)

Introduction (Cont.)

Example 1: Liquid Mixer

Example 1: Liquid Mixer (Cont.)

Wait for start button

Liquid start flow into vat

Liquid stop flow into vat

Motor Mixer on

Motor Mixer off

Start button ON

Pressure sensor ON

Temperature sensor ON

Start button OFF

5 STEPS4

TRANSITIONS

Example 2: Part Stamping System

One

cycleContinuous

Check mode

Wait for

start

Check for

part

Lock the

clamp

Press the

part

Unlock

clamp

Move

conveyor

Check for stop

PLC 5 STEP Applications!

Step 1: Understand the system operation.

Step 2: Identify number of input, output and special PLC operation.

Step 3: Sketch the timing diagram.

Step 4: Construct the Ladder Diagram (LD).

Step 5: Write the Instruction List (IL).

Application 1: Automatic Stacking Operation.

Develop the automatic stacking operationas in Figure. In this process, conveyor M1is used to stack metal plates onto conveyorM2. Conveyor M1 start when the STARTbutton is momentarily pressed. Sensor S1provide an input pulse to the PLC countereach time a metal plates drops fromconveyor M1 to M2. When 5 plates havebeen stacked, conveyor M1 stop andconveyor M2 is activated for 5 second bythe PLC timer. After conveyor M2 isoperated for 5 second, it stop cause thetimer and counter reset to automaticallyrestart conveyor M1. Your design shouldinclude ladder logic diagram dan timingdiagram. Briefly suggest and explain typesof sensor that can be used in your design.

STEP 1: Understand the system operation

Conveyor M1 is used to stack metalplates onto conveyor M2.

Conveyor M1 start when the STARTbutton is momentarily pressed.

Sensor S1 provide an input pulse tothe PLC counter each time a metalplates drops from conveyor M1 to M2.

When 5 plates have been stacked,conveyor M1 stop and conveyor M2 isactivated for 5 second by the PLCtimer.

After conveyor M2 is operated for 5second, it stop cause the timer andcounter reset to automatically restartconveyor M1.

STEP 2: Identify number of input, output and special PLC operation.

Conveyor M1 is used to stack metalplates onto conveyor M2.

Conveyor M1 start when the STARTbutton is momentarily pressed.

Sensor S1 provide an input pulse tothe PLC counter each time a metalplates drops from conveyor M1 to M2.

When 5 plates have been stacked,conveyor M1 stop and conveyor M2 isactivated for 5 second by the PLCtimer.

After conveyor M2 is operated for 5second, it stop cause the timer andcounter reset to automatically restartconveyor M1.

Device Label Address

Start PB1 %I0.0

Stop PB2 %I0.1

Sensor plate S1 %I0.3

Input:

STEP 2: Identify number of input, output and special PLC operation.

Conveyor M1 is used to stack metalplates onto conveyor M2.

Conveyor M1 start when the STARTbutton is momentarily pressed.

Sensor S1 provide an input pulse tothe PLC counter each time a metalplates drops from conveyor M1 to M2.

When 5 plates have been stacked,conveyor M1 stop and conveyor M2 isactivated for 5 second by the PLCtimer.

After conveyor M2 is operated for 5second, it stop cause the timer andcounter reset to automatically restartconveyor M1.

Device Label Address

Motor Conveyor 1

M1 %Q0.1

Motor Conveyor 2

M2 %Q0.2

Output:

STEP 2: Identify number of input, output and special PLC operation.

Conveyor M1 is used to stack metalplates onto conveyor M2.

Conveyor M1 start when the STARTbutton is momentarily pressed.

Sensor S1 provide an input pulse tothe PLC counter each time a metalplates drops from conveyor M1 to M2.

When 5 plates have been stacked,conveyor M1 stop and conveyor M2 isactivated for 5 second by the PLCtimer.

After conveyor M2 is operated for 5second, it stop cause the timer andcounter reset to automatically restartconveyor M1.

Device Address

Relay R

Counter C0

Timer T1

Others:

STEP 2: Identify number of input, output and special PLC operation.

Device Label Address

Start PB1 %I0.0

Stop PB2 %I0.1

Sensor plate S1 %I0.3

Input: Device Label Address

Motor Conveyor 1

M1 %Q0.1

Motor Conveyor 2

M2 %Q0.2

Output:

Device Address

Relay R

Counter C0

Timer T1

Others:

STEP 3: Sketch the timing diagram.

%I0.1Start

5s

%I0.2Stop

%I0.3Sensor 1

%Q0.1Motor 1

%Q0.2Motor 2

5s

STEP 4: Construct the Ladder Diagram (LD).

MEND

PB1%I0.0

R%M0.0

R%M0.0

PB2%I0.1

%M0.0

M1%Q0.1

M2%Q0.2

S1%I0.3

C0

CU

R

Q

5

C0.Q

T1

IN

PT

Q

T#5s

T1.Q

T1.Q

TP

CTU

PV

STEP 5: Write the Instruction List (IL).

Symbol Address Data Type

A I0.0 Bool

O M0.0 Bool

A NOT I0.1 Bool

= M0.0 Bool

A M0.0 Bool

A NOT T1.Q Bool

= Q0.1 Bool

A I0.3 Bool

A T1.Q Bool

C0 C0,5 Integers

A C0.Q Bool

T1 T1,5s Time

= Q0.2 Bool

MEND MEND

Start%I0.0

R%M0.0

R%M0.0

Stop%I0.1

%M0.0

M1%Q0.1

M2%Q0.2

S1%I0.3

C0

CU

R

Q

5

C0.Q

T1

IN

PT

Q

T#5s

T1.Q

T1.Q

TP

CTU

PV

Application 2: Packaging line control.

• When PB1 (START push button) is pressed, the box conveyor moves.

• Upon detection of box present, the conveyor stops and the apple conveyor starts moving.

• Part sensor, SE1 will count for 10 apples.

• Then, apple conveyor stops and box conveyor starts again.

• Counter will be reset and operation repeats until PB2 (STOP push button) is pressed.

START (PB1)

STOP (PB2)

STEP 1: Understand the system operation

• When PB1 (START push button) is pressed, the boxconveyor moves.

• Upon detection of box present, the conveyor stops and theapple conveyor starts moving.

• Part sensor, SE1 will count for 10 apples.

• Then, apple conveyor stops and box conveyor starts again.

• Counter will be reset and operation repeats until PB2(STOP push button) is pressed.

STEP 2: Identify number of input, output and special PLC operation.

Device Label Address

Start PB1 %I0.0

Stop PB2 %I0.1

Part Present SE1 %I0.3

Box Present SE2%I0.4

Input: Device Label Address

Apple Conveyor

M1 %Q0.1

Box Conveyor

M2 %Q0.2

Output:

Device Address

Relay R

Counter C0

Others:

STEP 3: Sketch the timing diagram.

Start (PB1)

Stop (PB2)

Part Present (SE1)

Box Present (SE2)

Relay (R)

Counter (C0)

Box Conveyor (M2)

Apple Conveyor (M1)

STEP 4: Construct the Ladder Diagram (LD).

MEND

PB1%I0.0

R%M0.0

PB2%I0.1

%M0.0

M2%Q0.2

SE2%I0.4

C0

CU

R

Q

10

SE2%I0.4

SE2%I0.4

SE1%I0.3

CTU

PV

R%M0.0

M1%Q0.1

%M0.0

C0.Q

C0.Q

STEP 5: Write the Instruction List (IL).

Symbol Address Data Type

A I0.0 Bool

O M0.0 Bool

A NOT I0.1 Bool

= M0.0 Bool

A M0.0 Bool

A NOT I0.4 Bool

O C0.Q Bool

= Q0.2 Bool

A M0.0 Bool

A I0.4 Bool

A NOT C0.Q Bool

= Q0.1 Bool

A I0.3 Bool

A I0.4 Bool

C0 C0,10 Integers

MEND MEND

PB1%I0.0

R%M0.0

PB2%I0.1

%M0.0

M2%Q0.2

SE2%I0.4

C0

CU

R

Q

10

SE2%I0.4

SE2%I0.4

SE1%I0.3

CTU

PV

M1%Q0.1

%M0.0

C0.Q

C0.Q

R%M0.0

Application 3: Conveyor Belt Motor Control

The PLC is used to start andstop the motors of segmentedconveyor belt. This allows onlybelt sections carrying an object(i.e. copper plate) to move.The position of copper plate isdetected by a proximity sensorswitch located next to eachbelt segment. As long as theplate is within the detectingrange of the sensor, the motorwill work. If the plate movesbeyond the range, a timer isactivated and when this settime has lapsed, the motor ofthe belt stops.

S7-1200

STEP 1: Understand the system operation

• The PLC is used to start and stop the motors of segmented conveyor belt.

• This allows only belt sections carrying an object (i.e. copper plate) to move.

• The position of copper plate is detected by a proximity sensor switch located next to each belt segment.

• As long as the plate is within the detecting range of the sensor, the motor will work.

• If the plate moves beyond the range, a timer is activated and when this set time has lapsed, the motor of the belt stops.

S7-1200

STEP 2: Identify number of input, output and special PLC operation.

Device Label Address

Start PB1 %I0.0

Stop PB2 %I0.1

Proximity Sensor 1

S1 %I1.1

Proximity Sensor 2

S2 %I1.2

Proximity Sensor 3

S3 %I1.3

Input:• The PLC is used to start and stop the

motors of segmented conveyor belt.

• This allows only belt sections carrying an object (i.e. copper plate) to move.

• The position of copper plate is detected by a proximity sensor switch located next to each belt segment.

• As long as the plate is within the detecting range of the sensor, the motor will work.

• If the plate moves beyond the range, a timer is activated and when this set time has lapsed, the motor of the belt stops.

STEP 2: Identify number of input, output and special PLC operation.

• The PLC is used to start and stop the motors of segmented conveyor belt.

• This allows only belt sections carrying an object (i.e. copper plate) to move.

• The position of copper plate is detected by a proximity sensor switch located next to each belt segment.

• As long as the plate is within the detecting range of the sensor, the motor will work.

• If the plate moves beyond the range, a timer is activated and when this set time has lapsed, the motor of the belt stops.

Device Label Address

MotorConveyor 1

M1 %Q0.1

MotorConveyor 2

M2 %Q0.2

MotorConveyor 3

M3 %Q0.3

Output:

STEP 2: Identify number of input, output and special PLC operation.

• The PLC is used to start and stop the motors of segmented conveyor belt.

• This allows only belt sections carrying an object (i.e. copper plate) to move.

• The position of copper plate is detected by a proximity sensor switch located next to each belt segment.

• As long as the plate is within the detecting range of the sensor, the motor will work.

• If the plate moves beyond the range, a timer is activated and when this set time has lapsed, the motor of the belt stops.

Device Address

Timer 0 T0

Timer 1 T1

Others:

STEP 3: Sketch the timing diagram.

%I0.0Start

Period

%I0.1Stop

%I1.1Sensor 1

%I1.2Sensor 2

%I1.3Sensor 3

%Q0.1Motor 1

%Q0.2Motor 2

%Q0.3Motor 3

Period

STEP 4: Construct the Ladder Diagram (LD).

T0

IN

PT

Q

T#20s

TOFF

T1

IN

PT

Q

T#20s

TOFF

Start%I0.0

Stop%I0.1

M3: %Q0.3

Q3: %Q0.3

Sensor 3%I1.3

M2: %Q0.2

M2: %Q0.2

M1: %Q0.1

M1: %Q0.1

T0.Q

T1.Q

Sensor 2%I1.2

Sensor 2%I1.2

Sensor 1%I1.1

STEP 5: Write the Instruction List (IL).

T0

IN

PT

Q

T#20s

TOFF

T1

IN

PT

Q

T#20s

TOFF

M3: %Q0.3

Sensor 3%I1.3

M2: %Q0.2

M2: %Q0.2

M1: %Q0.1

M1: %Q0.1

T0.Q

T1.Q

Sensor 2%I1.2

Symbol Address Data Type

A I0.0 Bool

O Q0.3 Bool

A NOT I0.1 Bool

= Q0.3 Bool

A I1.3 Bool

O Q0.2 Bool

A NOT T0.Q Bool

= Q0.2 Bool

A I1.2 Bool

T0 T0,20s Integers

A I1.2 Bool

O Q0.1 Bool

A NOT T1.Q Bool

= Q0.1 Bool

A I1.1 Bool

T1 T1,20s Integers

MEND

Sensor 2%I1.2

Sensor 1%I1.1

Start%I0.0

Stop%I0.1

M3: %Q0.3

Application 4: Measuring the Life of Cutting Knife

A knife is used to cut 3 products A, B and C and has to be change after cutting 1000 pieces ofA or 500 pieces of B or 100 pieces of C but the products come at random. A buzzer is soundwhen the life of the knife is up.

Tips: 3 sensors are assign to differentiate the 3 products. Another sensor is used to signalcutting completion. A pushbutton to start the process.

STEP 1: Understand the system operation

• Product A = 1000 pieces• Product B = 500 pieces• Product C = 100 pieces• Product come randomly

• Buzzer

• Consists of 3 sensors (Different product)• Complete cutting sensor• Start button

• Stop button

STEP 2: Identify number of input, output and special PLC operation.

Device Label Address

Start PB1 %I0.0

Sensor 1(Product A)

S1 %I1.1

Sensor 2(Product B)

S2 %I1.2

Sensor 3(Product C)

S3 %I1.3

Sensor 4(Cut sensor)

S4 %I1.4

Input:

• Product A = 1000 pieces• Product B = 500 pieces• Product C = 100 pieces• Product come randomly• Conveyor = 3 units• Consists of 3 sensors (Different product)• Complete cutting sensor

• Start button

• Product A = 1000 pieces• Product B = 500 pieces• Product C = 100 pieces• Product come randomly• Buzzer• Consists of 3 sensors (Different product)• Complete cutting sensor• Start button

• Cutter

STEP 2: Identify number of input, output and special PLC operation.

Device Label Address

Buzzer Buzz %Q0.0

Cutter Cut %Q0.1

Output:

STEP 2: Identify number of input, output and special PLC operation.

Device Address

Counter 1 C1

Counter 2 C2

Counter 3 C3

Reset I0.5

Others:• Product A = 1000 pieces• Product B = 500 pieces• Product C = 100 pieces• Product come randomly• Buzzer• Consists of 3 sensors (Different product)• Complete cutting sensor• Start button

• Cutter

STEP 3: Sketch the timing diagram.

%I0.0Start

X 100 = 1000%I0.1Sensor 1

%I0.2Sensor 2

%I0.3Sensor 3

%I0.4Sensor 4

%I0.5Reset

%Q0.0Buzzer

%Q0.1Cutter

X 50 = 500

X 10 = 100

STEP 4: Construct the Ladder Diagram (LD).

C1

CU

R

Q

1000

CTUSensor 1: %I0.1

PV

CU

R

Q

500

CTU

PV

CU

R

Q

100

CTU

PV

C2

C3

MEND

Reset: I0.5

Buzz: %Q0.0

Start Sensor 4: %I0.4Cutter: %Q0.1

%Q0.1

Sensor 2: %I0.2

Sensor 3: %I0.3

Reset: I0.5

Reset: I0.5

STEP 5: Write the Instruction List (IL).

Symbol Address Data Type

A I0.1 Bool

A I0.5 Bool

C1 C1,1000 Integer

O(

A I0.2 Bool

A I0.5 Bool

C2 C2,500 Integer

)

O(

A I0.3 Bool

A I0.5 Bool

C3 C3,100 Integer

)

= Q0.0 Bool

A I0.0 Bool

O Q0.1 Bool

A NOT I0.4 Bool

= Q0.1 Bool

MEND

C1

CU

R

Q

1000

CTUSensor 1: %I0.1

PV

CU

R

Q

500

CTU

PV

CU

R

Q

100

CTU

PV

C2

C3

MEND

Reset: %I0.5

Buzz: %Q0.0

Start: %I0.0 Sensor 4: %I0.4Cutter: %Q0.1

%Q0.1

Sensor 2: %I0.2

Sensor 3: %I0.3

Reset: %I0.5

Reset: %I0.5

Exercise 1

- Based on the Figure below, show the Sequential Functional Chart (SFC) and complete the PLC applications FIVE STEP using some information given.

Information:-

Input

- Start Button

- Stop Button

- Sensor 1 (X0)

- Sensor 2 (X1)

Output

- Motor Conveyor (Y1)

- Pushing Arm (Y0)

Exercise 1– Answer (SFC)

Wait for start button

Motor Conveyor (Y1) ON

Pushing Arm (Y0) OFF

Standing Bottle

Start button ON

Sensor detection

Sensor (X0) = 1Sensor (X1) = 1

Stop button ON

Motor Conveyor (Y1) OFF

Pushing Arm (Y0) ON

Drop Bottle

Sensor (X0) = 1Sensor (X1) = 0

Exercise 1– Answer (Timing Diagram)

Start

Stop

X0

X1

Y0

Y1

Exercise 1– Answer (LD & IL)

Y1 X0Y0

X1

MEND

StartY1

Stop

Y1

Symbol Address Data Type

A Start Bool

O Y1 Bool

A NOT Stop Bool

= Y1 Bool

A Y1 Bool

A X0 Bool

A NOT X1 Bool

= Y0 Bool

MEND

Exercise 2

The system is to short out theblack and white balls into 2different container. The startbutton will start, Ball sensor (S1)will sense the presence of theball in the hopper. The topsolenoid will release the ball forthis colour sensor (S2) todifferentiate the colour beforebeing release in to thecontainer.

Sensor 1

Sensor 2

Start

Stop

Exercise 2 – Answer (I/O assignment)

Device Label Address

Start PB1 %I0.0

Stop PB2 %I0.1

Sensor 1 S1 %I0.3

Sensor 2 S2%I0.4

Input:

Device Label Address

Relay R %M0.0

Top Cylinder TC %Q0.1

Bottom Cylinder

BC %Q0.2

Solenoid Cylinder

SC %Q0.3

Output:

Start

Stop

S1

S2

TC

BC

SC

Exercise 2– Answer (Timing Diagram)

Exercise 2– Answer (LD & IL)

%M0.0 %I0.3%Q0.1

%I0.4

MEND

%I0.0%M0.0

%I0.1

%M0.0

Symbol Address Data Type

A %I0.0 Bool

O %M0.0 Bool

A NOT %I0.1 Bool

= %M0.0 Bool

A %M0.0 Bool

A %I0.3 Bool

A NOT %I0.4 Bool

= %Q0.1 Bool

A %M0.0 Bool

A NOT %I0.3 Bool

A %I0.4 Bool

= %Q0.2 Bool

A %M0.0 Bool

A NOT %I0.4 Bool

= %Q0.3 Bool

MEND

%M0.0 %I0.3 %I0.4 %Q0.2

%M0.0 %I0.4%Q0.3

Thank You