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    Chapter 5 - PLC Application in The Industry

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    MOHD SABREE
    The document provides examples of PLC programs for conveyor control, material sorting, packaging control, traffic lights, and liquid filling/production. It includes ladder logic diagrams, input/output tables, and descriptions of how each system works by detecting sensors and controlling motors/valves based on the sensor states over time. The liquid filling example uses two level sensors and push buttons to control filling and emptying a tank while running a blender motor a set number of times.

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    Chapter 5 - PLC Application in The Industry

    Uploaded by

    MOHD SABREE
    443 views32 pages
    The document provides examples of PLC programs for conveyor control, material sorting, packaging control, traffic lights, and liquid filling/production. It includes ladder logic diagrams, input/output tables, and descriptions of how each system works by detecting sensors and controlling motors/valves based on the sensor states over time. The liquid filling example uses two level sensors and push buttons to control filling and emptying a tank while running a blender motor a set number of times.

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    Original Title

    CHAPTER 5 - PLC APPLICATION IN THE INDUSTRY

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    The document provides examples of PLC programs for conveyor control, material sorting, packaging control, traffic lights, and liquid filling/production. It includes ladder logic diagrams, input/output tables, and descriptions of how each system works by detecting sensors and controlling motors/valves based on the sensor states over time. The liquid filling example uses two level sensors and push buttons to control filling and emptying a tank while running a blender motor a set number of times.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    443 views32 pages

    Chapter 5 - PLC Application in The Industry

    Uploaded by

    MOHD SABREE
    The document provides examples of PLC programs for conveyor control, material sorting, packaging control, traffic lights, and liquid filling/production. It includes ladder logic diagrams, input/output tables, and descriptions of how each system works by detecting sensors and controlling motors/valves based on the sensor states over time. The liquid filling example uses two level sensors and push buttons to control filling and emptying a tank while running a blender motor a set number of times.

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    © All Rights Reserved
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    Download as ppt, pdf, or txt
    of 32

    DJM3072 - PROGRAMMABLE LOGIC

    CONTROLLER (PLC)
     This chapter will expose you to examples of PLC
    programs written in the application of automation
    control systems.
     Therefore, understanding the direction and
    format of PLC programming, such as ladder
    diagrams, mnemonic code and chart of sequence
    functions that have been discussed in chapter 4 is
    needed to help you review and analyze the
    examples of given program.
    1. Conveyor Motor Control Program
    2. Selection of Material Handling Systems
    (Part Sorting)
    3. Packaging Control System
    4. Simple Traffic Light Control Program
    5. Filling And Production Control
    6. Other related examples
    Figure 5.1 : Conveyor Motor Control
    • In this application (Figure 5.1), the PLC is
    used to start and stop the motor that used
    on the conveyor belt.
    • This allows any objects such as metal plate
    is moved from one part to another.
    • The position of a metal plate is detected by
    a proximity switch (type of sensor) located
    next to each conveyer 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 that belts stop.
    • Motor 2 will ON when sensor 3 detects the presence of object.
    • Motor 2 will OFF when motor 1 is ON and the object was
    outside the detection range of sensor 2.
    • Motor 1 will ON when sensor 2 detects the presence of object.
    • Motor 1 will OFF when the object was outside the detection
    range of sensor 1.
    Input Devices

    00000 Sensor 1 ( S1 )

    00001 Sensor 2 ( S2 )

    00002 Sensor 3 ( S3 )

    Output Devices

    10000 Motor 1 ( M1 )

    10001 Motor 2 ( M2 )

    10002 Motor 3 ( M3 )

    Table 5.1 : Assignment Table


    S3 ( 00002 ) TIM 000 M2

    10001 Motor 2
    M2 (10001)

    TIM 001 M1
    S2(00001)
    10000 Motor 1

    M1( 10000)

    M1(10000 ) 00001
    TIM 000
    # 0020 2 sec

    S1(00000) TIM 001


    04000

    04000

    04000 00000
    TIM 001 2 sec
    # 0020
    25313 (Normally closed)

    10002 Motor 3

    FUN (01)
    Address Instruction Data
    0000
    0001
    0002
    0003
    0004
    0005
    0006
    0007
    0008
    0009
    0010

    0011
    0012
    0013
    0014
    0015
    0016
    0017

    0018
    0019
    0020
    Address Instruction Data
    0000 LD 00002
    0001 OR 10001
    0002 AND NOT TIM 000
    0003 OUT 10001
    0004 LD 00001
    0005 OR 10000
    0006 AND NOT TIM 001 
    0007 OUT 10000
    0008 LD 10000
    0009 AND NOT 00001
    0010 TIM 000
    # 0020
    0011 LD 00000
    0012 OR 04000
    0013 AND NOT TIM 001
    0014 OUT 04000
    0015 LD 04000
    0016 AND NOT 00000
    0017 TIM 001
    # 0020
    0018 LD 25313
    0019 OUT 10002
    0020 FUN (01)
    Figure 5.2 : Selection of Material control system
     Figure 5.2 shows the control system of material
    selection. This application intended to detect
    the presence of a defective product group from
    the group were brought by the conveyor.

     Photoelectric Sensor 1 (PH1 - 00002) serves as


    the data input to the shift register. When the
    defective objects detected by the sensor,
    output signal on the sensor will be switched ON.
     Photoelectric Sensor 2 (PH2 - 00003) is used as
    the clock generator that serves as the clock
    input to the shift register.
     A pulse will be generated each time on the
    distance which is set at the initial.
     When a defective product is detected by the
    PH1, it is detected by the shift register until the
    product arrives at the designated position at the
    conveyor which will be triggered by a magnetic
    valve (MV - 10 000).
    Based on the given mnemonic code in the
    table below, write the ladder diagram.

    Address Instruction Data


    00000 LD 00000
    00001 LD 00001
    00002 LD 00002
    00003 SFT 100
        100
    00004 FUN (01 )  
    00000

    Set S
    SFT
    00001 100
    Pulse CP

    00002
    Reset R 100
    Figure 5.3 : Packaging Control System
    Table 5.3 : Assignment Table
     Referring to Figure 5.3 and Table 5.3, the
    box on the conveyor will move when PB1 is
    pressed.
     Conveyor Motor for box will stop and the
    conveyor motor for apples begin to move
    when the box is detected.
     Part Sensor will count up to 10 apples. After
    that the conveyor motor for apples will stop
    and conveyor motor for box will move again.
     Counter will be set (ON) and the operation
    will be repeated again until PB2 is pressed.
    PB1 (00000 ) PB2 (00001)
    01000
    01000

    01000 10001
    10000
    SE1 (00002)

    SE2 (00003) CNT 010


    # 0010
    CNT 010 01000
    10001

    SE2 (00003)

    END(01)
    Address Instruction Data
    0000 LD 00000
    0001 OR 01000
    0002 AND NOT 00001
    0003 OUT 01000
    0004 LD 01000
    0005 AND NOT 10001
    0006 OUT 10000
    0007 LD 00002
    0008 LD NOT 00003
    0009 CNT 010
        #0010
    0010 LD CNT 010
    0011 OR NOT 00003
    0012 AND 01000
    Figure 5.4 : Traffic Light Control
     Figure 5.4 shows the traffic light control
    installed on a road that is being repaired.
     A pair of opposite traffic lights installed in
    two road routes to control traffic congestion.
    The lights will operate alternately.
     When the traffic lights green L1, L2 traffic
    lights will show red and the reverse will be
    repeated.
     Conversion of each lamp flame is controlled
    by a timer for 30 seconds.
    TIM 001
    TIM # 0300
    000

    TIM 000
    TIM # 0600
    001
    TIM 000
    # 0150
    10000

    10000
    # 0150
    10001

    10001
    TIM # 0150
    002
    TIM 002
    TIM # 0300
    003
    TIM 002 TIM 003
    10002

    10002
    10003

    END(01)
    Address Instruction Data
    00000 LD NOT TIM 001
    00001 TIM 000
        #0300
    00002 LD TIM 000
    00003 TIM 001
        #0600
    00004 LD NOT TIM 000
    00005 OUT 10000
    00006 LD NOT 10000
    00007 OUT 10001
    00008 LD 10001
    00009 TIM 002
        #0150
    00010 LD TIM 002
    00011 TIM 003
        #0300
    00012 LD TIM 002
    00013 AND NOT TIM 003
    00014 OUT 10002
    00015 LD NOT 10002
    00016 OUT 10003
    00017 FUN 01  
    Figure 5.5 : Filling And Production Control
     Figure 9.5 shows the operational control of
    liquid level in a tank. In this process, two
    sensors (TLB1 and TLB2) is used to detect
    liquid level which flow into the tank.

     MVI valve functioning as a controller for


    input of liquid through a pipe and MV2 valve
    will control the output of liquid.
    1. When the push-button start (PB1) is pressed, MV1
    valve will be open and the liquid will flow into the
    tank. At the same time, the blender motor begin
    function.
    2. When the liquid passes TLB2 and hit the TLB1, MV1
    valve will shuts off and the blender motor will stop.
    3. When PB1 is pressed again, the valve MV2 will be
    open and fluid will be flow out of the tank. MV2 will
    be close when the liquid level was below the TLB2.
    4. Once the process repeated four times, the Level
    Indicator light (PL) will be off . The process of filling
    and production of liquid at the tank will be stopped
    even if PB1 is pressed.
    INPUT OUTPUT

    00000 – Push Button Start (PB1) 10000 – Water Supply Valve. (MV1)

    00001 – Push Button Stop (PB2) 10001 – Water Release Valve (MV2)

    00005 – Top Level Switch (TLB1) 10002 – Blender Motor (M)

    00006 – Bottom Level Switch (TLB2) 10004 – Level Indicator

    10005 - Buzzer

    Table 5.5 : Assignment table

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