Bansilal Ramnath Agarwal Charitable Trust’s

VISHWAKARMA INSTITUTE OF TECHNOLOGY, PUNE –

411037
(An Autonomous Institute under University of Pune)

Name: Ayush Yadav TYME_D

Roll no: 55
Prn no: 12011162

Experiment 3- PLC Programming

Aim -

To Study Of Operation Of A+, B+, A- , B- Of Single Acting Cylinder & Double Acting
Cylinder Through Plc Programming.

Theory –
The technology of pneumatics deals with the study of the behaviour and
application of compressed air. Today, air operated tools and accessories are a common
sight in every industry, not only in technologically advanced countries but even in countries
where industrial activities are still at the stage of sheer infancy. With the introduction of
pneumatics in manufacturing process, the industry is benefited with a cheaper medium off
industrial automation, which if judiciously used, may bring down the cost of production to a
much lower level. Now, compressed air is used in every walk of industrial life, starting with
pneumatic cranes to the use of air in the brake system of automobiles, railway coaches,
wagons, printing presses and what not.

Compared to hydraulic system, pneumatic system has better operational

advantages but it cannot replace hydraulic system so far as power requirement and
accuracy of operations are concerned.

Basic System -
In modern industries, pneumatic system is used as a means of workplace
mechanization and automation where a major part of manual and tedious work may be
supplemented by pneumatic controls for quick and economic production. The basic system
requirements for introducing pneumatics in one’s plant are listed below -

1. Compressor plant

2. Pipe line

3. Control valves

4. Air actuator

5. Auxiliary appliances
Different Components In The Trainer -

1. AFR Unit -
The air that is sucked by the air compressor is evidently not clean because of the
presence of various types of contaminants in the atmosphere; moreover, the air that is
supplied to the system from the compressor is further contaminated by virtue of
generation of contaminants downstream. Hence, to enable supply of clean pure and
contamination free compressed air, the air requires to be filtered.

The three main elements of an AFR unit are

 Air filter
 Pressure regulator
 Lubricator

Fig 1. AFR Unit

2. PNEUMATIC
CYLINDERS -

Pneumatic cylinders offer a straight rectilinear motion to mechanical elements.

Cylinders are classified as light, medium, and heavy duty with respect to their application.
The pneumatic power is converted to straight line reciprocating motions by pneumatic
cylinders. According to the operating principle, air cylinders can be subdivided as

 Single acting Cylinder

 Double acting cylinders.

Fig 2. Single Acting Cylinder

Fig 3. Double Acting Cylinder

 3. PNEUMATIC VALVES -
The pneumatic energy is regulated and controlled by pneumatic valves. Valves are
divided into four major groups, viz., direction control, flow control, pressure control,
pressure control, nonreturn and special type valves. Direction control valves are
classified functionally as 2/2, 3/2, 4/2, 5/2, 4/3, 5/3, etc. depending upon the number of
port openings and valve positions. Valves are actuated in various methods, viz.,
manually, mechanically, electrically, pneumatically and by various combined modes of
actuation.

Valves are used to -

 Start and stop pneumatic energy;

 Control the direction of flow of compressed air
 Control the flow rate of compressed air and
 Control the pressure rating of the compressed air
3.1 DIRECTION CONTROL VALVES:

Direction control valves are used mainly to direct the flow of the pressure fluids in the
desired directions. The main functions of these valves are to start, stop and regulate
the direction of airflow and help distribution of air in the desired line.

There are two types of DC valves -

Fig 4. 3/2 Hand Lever Valve Fig 5. 5/2 Hand Lever Valve

4. PNEUMATIC MOTOR -
To generate rotational motion in pneumatic system, a pneumatic motor is used.
Pneumatic motors have been found to provide very high rotational speed, which sometimes
may go up to 10,000 revolutions per minute or even more. Air motors are of various types of
designs, but the most common one is the vane type. In vane type air motors rotor is placed
interior of the casing. The rotor block has a number of finely machined, ground & polished
slots into which small vanes are placed, which can move in & out of the rotor slots. When
compressed air is fed the rotor starts rotation, there by producing torque on the shaft, air
motor offers an extremely safe system due to their capability to dissipate the heat owing
to expansion of the air inside the vane chambers. This is a very advantageous property of
air motor over electrical motors.

Other design types are -

 VANE MOTORS
 PISTON TYPE MOTORS
 TURBINE MOTORS
  GYRATOR

5. SOLENOID OPERATED DIRECTION CONTROL VALVE

Solenoid is another name for electromagnet. A magnetic force can be temporarily
developed in an electromagnet when a current is allowed to pass through it. There will be
no force, when the current is switched off. Solenoids are used to actuate pneumatic valves
e.g. direction control valve. In a three-way direction control valve which is solenoid controlled,
three valve ports are P, A, R. Normally, the spool blocks air from P to A. when an electric current is
passed through the coil of solenoid, the valve spool lifts & P opens to A. if the electric current
is switched off, the spool returns to its normal position, P closes to A & A opens to R.

Fig 6. 3/2 Solenoid Valve Fig 7. 5/2 Solenoid Valve

6. AIR MANIFOLD -
The Manifold distributes air from hoses attached to each side of the unit. Several trunk
lines lead off the Main Air Manifold. They are connected to the components using PU tube.
The air flow from the compressor is controlled using the AFR UNIT and then distributed as
per the designed Pneumatic Circuits.

Fig 8. Air Manifold

7. FLOW CONTROL VALVE -
Speed control in pneumatic system is achieved by means of a flow control valve. This is done
by constricting or throttling a flow passage so that part of the air supply is obstructed in the
area of constriction. In most cases of pneumatic system, the flow control valve is
constructed with an inbuilt
check valve so that the controlled flow is directed only in one direction and the reverse flow
through the valve is free. This means that whenever we use such valve in pneumatic system,
we get flow control and thereby speed control of air cylinder or motor only in one direction.

Flow control valves are available in two modes:

 Fixed flow control

 Variable flow control

In variable flow control valve, an adjustable control needle is positioned at any

place of the flow passage to regulate the flow as per need of flow quantity. This is done by
screwing a taper needle inside the control passage.

Fig 9. Flow Control Valve

8. NON-RETURN VALVE -
These types of valves are one-way control valves. The medium through this valve can
only flow in one-way. It has reasonable design & simple structure with wide application.
These valves are known for durability and maximum efficiency. This helps to provide high
quality and low-cost alternatives in fluid and gaseous control systems of different
application.

Fig 10. Non- Return Valve

 9. PROXIMITY SENSOR
Proximity sensors or switches are pilot devices that detect the presence of an object
without physical contact. They are solid state electronic devices that are completely
encapsulated to protect against excessive vibration, liquids, chemicals, and corrosive agents
found in the industrial environment.

Fig 11. Proximity Sensor

10. PRESSURE GAUGE

In Pneumatic circuits, Pressure Gauge is used to measure the pressure of
compressed air. The pointer rotates on a calibrated scale whose reading gives the amount of
Air Pressure. Today Pressure Gauge is among the most commonly used instruments. We
can see numerous applications using Pressure Gauges, such as, pumps, Hydraulic & Pneumatic
circuits, Boilers and pressurized vessels. Electric and pneumatic time delay
valves are used for precise controlling of connections and systems, as they can delay,
impose time limits on or interrupt specific processes (i.e., pump operation) for pre-set time
intervals.

Fig 11. Pressure Gauge

ISO SYMBOLS FOR PNEUMATIC
COMPONENTS
INTRODUCTION TO PLC
A Programmable Logic Controller, which is usually called a PLC or, more commonly,
simply a programmable controller, is a solid-state, digital, industrial computer. Upon first
glance, a programmable controller may seem to be no more than a block box with wires
bringing signals in & wires sending signals out. The PLC is a computer; however, without a
set of instruction telling it what to do, it is nothing more than a box full of electronic
components. The user program is the list of instructions that tells the PLC what to do.
Computers such as PLC’s can be wonderful tools; however, although it might appear
otherwise, they only do exactly what the human programmer told them to do.

WHAT IS A PROGRAMMABLE LOGIC CONTROLLER (PLC)?

The programmable logic controller (PLC), or programmable controller, can be

classified as a solid-state member of the computer family. A programmable controller is an
industrial computer in which control devices such as limit switches, push buttons, proximity or
photoelectric sensors, float switches, or pressure switches, to name a few, provide incoming
control signals into the unit. An incoming control signal is called an Input. Incoming control
signals, or inputs, interact with instructions specified in the user ladder program, which tells
the PLC how to react with the incoming signals. The user program also directs the PLC on
how to control field devices like motor starters, pilot lights, & solenoids. A signal going out of
the PLC to control a field device is called an Output. Figure 1 gives an overview of the
interaction between SW 1 (the systems input), the PLC & its ladder program, & the pilot light
output.

WHAT MAKES A PLC WORK?

The heart of any computer is the microprocessor. The computer’s microprocessor,

also called the processor or central processing unit (CPU), supervises system control
through the user program. The microprocessor reads input signals & follows the instructions
that a programmer has stored in the PLC’s memory. As a result of the solved program, the
PLC turns outputs, or field-controlled devices, ON or OFF. When the PLC is running &
following the programmer’s instructions, this is called solving the user program.

A programmable controller is made up of the following sections, each of which has a

unique job in its operation.

The sensing section: The sensing section is made up of limit switches, pressure switches,
photoelectric sensors, push buttons, & so forth. These incoming hardware devices provide
input signals. Devices such as the push button, limit switch or photoelectric sensor are field input
devices. The term “field input” refers to hardware items providing incoming signals that are
tangible items that you physically connect to the PLC.

Input section: The input section of the PLC contains two major areas. First, the physical
screw terminals where incoming signals (inputs) from field input devices like a limit switch,
for example, are attached to the PLC. Figure-6 illustrates a product sitting on a conveyor.
When the conveyor moves the product into position, the sensor will send an input into input
screw terminal number zero on the PLC input section. The second portion of the input section is
the PLC’s internal conversion electronics. The function of the input section- voltage input
level from field devices. High-voltage signals 23 from field devices are converted to +5 volts
direct current (VDC) for a valid ON input signal, & 0VDC for a valid OFF input signal.
Incoming signal conversion & isolation are necessary as the solid-state microprocessor
components operate on +5 VDC whereas input signal may be 24VDC, 120 volts
alternating current (VAC), or 220VDC. Inputting a120 VAC signal, for example, into a 5VDC
circuit will quickly destroy your PLC.

Controller: The controller is commonly called the central processing unit (CPU) or, simply,
the processor. This is the brain, or microprocessor, that controls or supervises the entire
process. The CPU solves the user program & updates the outputs.

Programmer: The programmer is the device whereby the programmer or operator can
enter or edit program instructions or data. The programmer can be handheld unit.

Output Section: The result of looking at, or reading, the ON or OFF status of the inputs &
using this information to solve the user ladder program is to send updated signals to the
output section. The output section is simply a series of switches, one for each output point, that
are controlled by the CPU & are used to turn output field devices ON or OFF.

Field hardware devices: The motor starter is the device controlled by the PLC. The devices
that are controlled by the PLC’s output section screw terminals are the field hardware
devices.

PHOTOGRAPH OF THE TRAINER

Fig 12. PLC BASED ELECTRO- PNEUMATIC TRAINER KIT

 PLC BASED EXPERIMENT SELECTION CHART

Fig 13. PLC Based Experiment Selection Chart

Statement –
STUDY OF OPERATION OF A+, A-, B+, B- OF SINGLE ACTING CYLINDER & DOUBLE ACTING
CYLINDER THROUGH PLC PROGRAMMING.

1. Symbolic Diagram:
 Fig 14. Symbolic Diagram

2. Pneumatic Diagram:

Fig 15.
Pneumatic
3. PNEUMATIC
Diagram
CONNECTION:

1. Connect AFR pneumatic pipe to Inlet of Air Manifold

2. Connect AIR Manifold pneumatic pipe to port IN of 3/2 Solenoid valve & 5/2 Solenoid
Valve
3. Connect Port Out of 3/2 Solenoid valve extracting port IN of single acting cylinder.
4. Connect Port A of 5/2 Solenoid Valve extracting port A of Double acting cylinder.
5. Connect Port B of 5/2 Solenoid Valve retracting port B of Double acting cylinder.
4. ELECTRICAL CONNECTION:

 Connect +24VDC & -24VDC on PLC unit to +24VDC & GND test point on Power
Supply Unit
 Connect +24V DC to the +24V DC (red) of PS1, PS2, PS3 & PS4
 Connect -24V DC (GND) to the -ve terminal/GND (Black) of PS1, PS2, PS3 & PS4
 Connect O/P (Yellow) of the PS1to the I1on PLC Unit • Connect O/P (Yellow) of the
PS2 to the I2 on PLC Unit
 Connect O/P (Yellow) of the PS3 to the I3 on PLC Unit
 Connect O/P (Yellow) of the PS4 to the I4 on PLC Unit
 Connect GND (Black) test point on panel to GND point on 3/2 SV
 Connect GND (Black) test point on panel to GND point on 5/2 SV
 Connect Q1(Yellow) From PLC panel to +24V DC (red) 3/2 SV.
 Connect Q2 (Yellow) From PLC panel to+24V DC (red) on 5/2 SV respectively.

5. PROCEDURE: -
1. Connect the compressor to the AFR.
2. Start the compressor, set the desired pressure through the AFR.
3. Do the pneumatic connections as shown above.
4. Plug the trainer supply wire in socket(230VAC,50Hz)
5. Operate Toggle switch I6 (ON), I7 (OFF) & I8 (OFF) on PLC panel.
6. Observe the A+, A-, B+, B- operation of two cylinders by PLC Control method.
7. Vary the air flow through flow control valves mounted on Single Acting Cylinder
and Double acting cylinder for speed control of reciprocating.

Output -
Conclusion:
In this experiment, we have studied Programmable Logic Controller (PLC) Programming
and basic system requirements and successfully carried out Operation Of A+, B+, A- , B- Of
Single Acting Cylinder & Double Acting Cylinder Through Plc Programming.