KONGU ENGINEERING COLLEGE, PERUNDURAI, ERODE - 638 052

(Autonomous)

SCHOOL OF BUILDING & MECHANICAL SCIENCES

DEPARTMENT OF MECHATRONICS ENGINEERING

MODEL EXAMINATION-APRIL 2018

Programme : B.E
Date : 04.04.18
Branch : Mechatronics Engineering
Time : 08.00 a.m. to 5.00 p.m.(3batches/day)
Semester : VI
Course Code : 14MTL63 Duration : 3Hours/batch
Course Name : Programmable Automation Maximum Marks : 100
controller Laboratory

Batch I (08.00 a.m. to 11.00 a.m.)

1. Write a ladder logic program and HMI screen for following: Use the timing diagram
below to design ladder logic. The sequence should start when input X turns on. X may
only be on momentarily, but the sequence should continue to execute until it ends at 26
seconds.

2. A conveyor line is to be controlled with either a variable frequency drive, or a brushless

servo motor. Workers will place boxes on the inlet side of the conveyor; these will be
detected with a ‘box present’ sensor. The box position is also detected with an ultrasonic
sensor with a range from 10cm to 1m. When present, boxes on the conveyor will be moved
until they are 55cm from the sensor. Once in place, the system will stop until the box is
removed. After this, the process can begin again when a new box is detected. Design all of
the required ladder logic for the process.

3. Develop a ladder program for following case and implement by using

Micrologix 1200 PLC. A machine has been built for filling barrels. Use
process sequence bits to design ladder logic for the sequential process
as described below.
i. The process begins in an idle state.
ii. If the ‘fluid_pressure’ and ‘barrel_present’ inputs are on, the system
will open a flow valve for 2 seconds with output ‘flow’.
iii. The ‘flow’ valve will then be turned off for 10 seconds.

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 iv. The ‘flow’ valve will then be turned on until the ‘full’ sensor
indicates the barrel is full.
v. The system will wait until the ‘barrel_present’ sensor goes off
before going to the idle state. Note: PLC input wiring
connection should be PNP concept.

4. Packages are conveyed past a linear measuring device on a on a roller conveyor in order
to establish their size. There are two different package sizes: Short and long packages. The
linear measuring device supplies an 0-signal for a short package and a 1-signal for a long
package.
Following this, the packages reach a lifting platform. The sequence is started by means of
START button S1. The packages are lifted by a lifting cylinder 1.0. The packages are then
sorted: Short packages are transferred to a second conveyor via transfer cylinder 2.0, and
long packages onto a third conveyor via cylinder 3.0. Lifting cylinder 1.0 is to retract again
only after cylinders 2.0 or 3.0 have reached their end position.
The cylinder positions are monitored by means of proximity switches B1 to B6. Cylinder 1.0
is advanced and retracted by means of a double solenoid valve via coils Y1 and Y2.
Cylinders 2.0 and 3.0 are advanced and retracted by means of solenoid valves (coils Y3 and
Y4).

5. Write a ladder logic program and HMI screen for following:

That will turn on an output Q five seconds after an input A is turned on. If input B is on the
delay will be eight seconds. YOU SHOULD ONLY USE ONE TIMER.

6. A roller conveyor is monitored by a proximity switch B1 as to whether a package is

present. If this is the case, the package is picked up by a cylinder 1.0 (lifting cylinder) and
then transferred to another conveyor by means of cylinder 2.0 (transfer cylinder).
Cylinder 1.0 is to retract first, followed by cylinder 2.0. The cylinders are retracted and
advanced by means of solenoid valves (coils Y1 and Y2). The cylinder positions are
monitored by means of proximity switches B2 to B5.
On the feed side, packages have been previously arranged in such a way that they reach the
lifting device individually.

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 7. Develop a suitable ladder program for Temperature control process
 Implement by using 1400 PLC
 Find out the signal conditioning output voltage of following temperature range 33.02 ̊ C,
40 ̊ C, 49.85 ̊ C, 55.09 ̊ C, 58 ̊ C,62.6 ̊ C and store the values in any register.
 The output voltages and temperatures are should be display in HMI screen.

8. A simple air conditioner consists of a single air compressor motor which gets switched
off when temperature of the space being controlled falls below the setting on the thermostat.
Thermostats are provided with a differential setting to avoid on and off of the compressor
motor.
The three stage air conditioning system helps in conservation of electrical power.
There are two motors compressors in the system. One is of low horsepower and other one is
of high horsepower rating. These motors are designated as C1 and C2 in the case. The system
is installed in a hall to maintain the temperature between 200C-240C depending on the
number of viewers in the hall and the atmospheric temperature.
The motors of C1 and C2 are run on three conditions of the thermostats. The three conditions
described below are also the control requirements of the air conditioning system:-
i. Compressor 1 and compressor 2 should turn on when the temp. of the hall is above
280C
ii. Only compressor 2 should turned on when the temp. of the hall is above 240C and
below 280C.
iii. Only compressor 1 is turned on when the temp. is above 200C and below 240C.
A pre- condition for running any compressor is that chilling water flow switch FS1 should be
closed. Chilling water flow necessary to take away heat from the compressed cooling water.
Three thermostats with different settings are used for the control of compressor motor
running In three different stages described above.
The three thermostats T1, T2, T3, are set at temp 200C, 240C and 280C respectively.
The start push button, stop push button and overload contacts for compressor motor have not
been shown in the circuit for sake of simplicity.

9. (a). Construct and execute ladder program for the given case by using Micro810 PLC.
Simplify the following Boolean functions
i. A’B’C’D’+AC’D’+B’CD’+A’BCD+BC’D
ii. ABC’+AB’D+(B’C’D’)’
(b). To perform the Math operation for the case study as shown in figure and to calculate
the following.
i. to calculate the total no of balls that is falling in both baskets
ii. knowing the total no of balls and no of white balls calculate no of black balls

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 iii. to glow an LED when 75% of the basket is filled by black balls to change the
basket.
(Assume basket capacity is 500 balls)

10. Develop a suitable PLC program for the following sequence

a) Turn on light 1 if the no of component in box is less than 4
b) Turn on light 2 if the no of component in the box is equal to 4
c) Turn on light 3 if the no f component in the box is greater than 4
d) Turn on light 4 if the no of component in the box is less than or equals to 4
e) Turn on light 5 if the no of component in the box is greater than or equals to 4
(Assume suitable input and outputs)
Develop a HMI screen for inputs, outputs, data compare instructions and registers.

11. The following figure represents an industrial operation of thermal processing of metals,
the machine hardens the metal in the shape of a steel ring. the hardening process is done by
heating the steel ring to a very high temperature, then it goes through a sudden cooling. So
the piece we want to harden is heated by passing very high currents through a coil that heats
the piece, then we cool it very quickly by sending cold water through the holes in each side.

This process is summarized as following:

i. When the main push button is pressed, the system is activated.
ii. The piece is put in its place (on spindle)

iii. Pressing two push buttons (the left and the right) to start the process.

iv. The system can be deactivated (off) completely and quickly by OFF push button.

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 v. The piece goes from down to above through an air-cylinder that works by a
Solenoid valve. it comes back after the valve has been disconnected by the Spring
or by the falling weight (gravity). this will not happen, of course, unless the piece
exists, which is known using the sensor LSPP which detects the piece (i.e.
working piece).

vi. The spindle activates the switch LSU when it reached it.

vii. Then the heat will start for only 10 seconds.

viii. After that, cooling starts and lasts only 10 seconds.

ix. The piece returns to the bottom by the gravity, after the Solenoid valve has been
disconnected. Then the LSU returns to the normal state – normally open (NO) –
after the piece has gone down, The system after that will be in a RESET state.

x. Then we could put a new piece and repeat the whole process.

12. Conduct suitable Experiment for Networking of PLC

Consider the following for conducting experiment:
 Develop a single HMI screen to control (Start & stop) the PLCs which
connected within the network.
 If any timers and counters used in program, the timers and counters acc. values
should be in HMI screen.

13. Develop a suitable PLC program for following operation a pump is to be used to fill two
storage tanks .The pump is manually started by the operator from a START/STOP button. When
the first tank is full, the control logic must be able to automatically stop the flow to the first tank
and direct the flow to the second tank. When the second tank is full, the pump must shut down
automatically. (Assume suitable input and outputs)

14. In this machine, the work piece or the job placed on the table moves to and fro by rack and
pinion arrangement mounted on the shaft of the squirrel cage motor. Here the cutting tool is fixed
while the job placed on the table is worked upon by the movement of table. Movement of the
table is controlled between two limits left and right by switches 1LS and 2LS. When the table
moves left to right, tool works on the job while it remains ideal during right to left motion of the
table. At the end of right to left motion, tool gets feed for the next cut on the job. Various control
requirements for the job are as follows:-
i. The motor is to be start manually by pressing start push-button. Once the motor starts it
reversed automatically at the end of right or left stroke by limit switches2LSand1LS.
ii. There should be provision of jogging the motor by jog push button.
iii. If the machine table is lying in between extreme position, machine should fail to start.
Selection of initial direction of travel should be possible through right and left push button,
PBR and PBL.
iv. There should be delay in starting the motor in left to right stroke so as to allow the tool to get
the feed for the fresh cut on the job.
v. The machine should stop on pressing the stop push –button or on over load tripping of motor.

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 vi. Interlocking of coolant pump motor(running) should be provided as a precondition for the
starting of machine.

15. We will implement a control program that detects the position of a bottle via a limit switch
then waits for 0.5 secs, and then fills the bottle until a photo detector detects the filled
condition of the bottle. After the bottle is filled, the buzzer sounds and the control program
will again wait for 0.7 secs. before moving to the next bottle .Until the limit switch signals
,the feed motor,M1 runs while there are fixed rollers which carries the filled bottles.
Motor,M2 keeps running after the process has been started.

Fig. Bottle Filling System

16. Write a ladder logic program. That will turn on an output Q five seconds
after an input A is turned on. If input B is on the delay will be eight seconds.
YOU SHOULD ONLY USE ONE TIMER.

17. Develop a ladder diagram for three road traffic light controller by using micro810 PLC.
(Note: PLC wiring connection is must)
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18. Develop a ladder program for following case:
This morning you received a call from Mr. Ian M. Daasprate at the Old
Fashioned Widget Company. In the past when they built a new machine
they would used punched paper cards for control, but their supplier of
punched paper readers went out of business in 1972 and they have
decided to try using PLCs this time. He explains that the machine will dip
wooden parts in varnish for 2 seconds, and then apply heat for 5 minutes
to dry the coat, after this they are manually removed from the machine,
and a new part is put in. They are also considering a premium line of parts
that would call for a dip time of 30 seconds, and a drying time of 10
minutes. He then refers you to the project manager, Ann Nooyed.

You call Ann and she explains how the machine should operate. There
should be start and stop buttons. The start button will be pressed when
the new part has been loaded, and is ready to be coated. A light should be
mounted to indicate when the machine is in operation. The part is
mounted on a wheel that is rotated by a motor. To dip the part, the motor
is turned on until a switch is closed. To remove the part from the dipping
bath the motor is turned on until a second switch is closed. If the motor to
rotate the wheel is on for more that 10 seconds before hitting a switch,
the machine should be turned off, and a fault light turned on. The fault
condition will be cleared by manually setting the machine back to its
initial state, and hitting the start button twice. If the part has been dipped
and dried properly, then a done light should be lit. To select a premium
product you will use an input switch that needs to be pushed before the
start button is pushed. She closes by saying she will be going on vacation
and you need to have it done before she returns.
You hang up the phone and, after a bit of thought, decide to use the
following outputs and inputs,
INPUTS
I/1 - start push button
I/2 - stop button
I/3 - premium part push button
I/4 - switch - part is in bath on wheel
I/5 - switch - part is out of bath on wheel
OUTPUTS
O/1 - start button
O/2 - in operation
O/3 - fault light
O/4 - part done light
O/5 - motor on
O/6 - heater power supply

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8
 Batch II (11.00 a.m. to 02.00 p.m.)

1. Write a ladder logic program and HMI screen for following: Use the timing diagram
below to design ladder logic. The sequence should start when input X
turns on. X may only be on momentarily, but the sequence should execute anyway.

2. To perform the Math operation for the case study as shown in figure and to calculate the
following.
 To calculate the total no of balls that is falling in both baskets
 Knowing the total no of balls and no of white balls calculate no of black balls
 To glow an LED when 75% of the basket is filled by black balls to change the
basket.
(Assume basket capacity is 500 balls)
 Develop a HMI screen for the above.

3. Develop a ladder program and HMI screen for the following case:
A machine ejects parts into three chutes. Three optical sensors (A, B and C) are positioned in
each of the slots to count the parts. The count should start when the reset (R) button is pushed.
The count will stop, and an indicator light (L) turned on when the average number of parts
counted equals 100.

4. Conduct suitable Experiment for Level control by using micro830 PLC.

5. Construct and execute ladder program for the given case:

Use a Double Directional control valve to operate a double acting cylinder in FWD and RET
stroke.
 Provide only momentary signal for solenoid actuation
 Implement in Micro830 PLC
 PLC wiring connection must be in sourcing concept

6. Construct a traffic light sequence for a three road junction with pedestrian crossing.
Develop HMI screen for four road traffic lights.

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7. Develop a suitable PLC program for math instruction ax2+ bx+c if the sum of the above
instruction is equal to 10 turn on light 2 else turn on light 1.
 By using Micrologix 1000 PLC.
 Develop HMI screen for the above case.

8. Operate an electrical switch to make a double acting cylinder to attain FWD stroke.(Use
double solenoid valve to operate the cylinder). RET stoke should be automatic as soon as it
reaches the FWD end position.
 Implement in Micro830PLC
 PLC input wiring connection must be in sourcing concept

9. Develop a suitable ladder program for Temperature control process and implement in
Micrologix in 1400 PLC. Set temperature is 57 ̊ C (± 3 ̊ C)

10. Develop a suitable ladder program for Flow control process by using micro830 PLC
 Valve opening percentage should be 50%, for input current to the I to P
converter is 12mAh.

11. Develop a ladder program for speed control of AC motor by using Power flex 40 drive.
 The AC motor should run at maximum speed, if the analog input voltage is +5V
 The AC motor should run at minimum speed, if the analog input voltage is +0V
 The AC motor should not run, if the analog input voltage is not met above conditions
Consider the following to develop a program:
 Analog input of PLC is 0-5V DC(Not exceed +5VDC)
 Analog output of PLC is voltage form.
 Analog input of drive is 4-20mA
 The maximum speed of ac motor 1400 rpm.
 Only 4-20mA to be given to the drive(Not 0-10VDC)
 Develop a HMI screen for the following parameters:
 Start and stop push button
 Input of PLC
 Output of PLC
 Input of drive
 Feedback output of drive

12. Develop a suitable ladder program for speed control of DC motor by using Micrologix
1400PLC.
Consider the following to develop a program:
 Analog input of PLC is 4-20mA
 Analog output of PLC is 4-20mA
 Analog input of drive is 0-10VDC
 The maximum speed of DC motor 1330 rpm.
 Only 0-10VDC to be given to the drive(Not 0-20mA)
 Develop a HMI screen for the following parameters:
 Start and stop push button, Input of PLC, Output of PLC, Input of drive,
Feedback output of drive

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13. The response times of hydraulic switches is being tested in a PLC controlled station. When
the units arrive a ‘part present’ sensor turns on. The part is then clamped in place by turning on a
‘clamp’ output. 1 second after clamping, a ‘flow’ output is turned on to start the test. The
response time is the delay between when ‘flow’ is turned on, and the ‘engaged’ input turns on.
When the unit has responded, up to 10 seconds later, the ‘flow’ output is turned off, and the
system is allowed to sit for 5 seconds to discharge before unclamping. The result of the test is
written to one of the memory locations from F8:0 to F8:39, for a total of 40 separate tests. When
40 tests have been done, the memory block from F8:0 to F8:39 is sent to another PLC using
DH+, and the process starts again. Write the ladder logic to control the station.

14. Controls are to be developed for a machine that packages golf tees.
Each container will normally hold 1000 tees filled from three different
hoppers, each containing a different color. For marketing purposes the
ratio of colors is changed frequently. To make the controller easy to
reconfigure, the number of tees from each hopper are stored in the
memory locations N7:0, N7:1 and N7:2. The process is activated when an
empty package arrives, activating a PRESENT input. When filling the
package, the machine opens a single hopper with a solenoid, and counts
the tees with an optical sensor, until the specified count has been
surpassed. It then repeats the operation with the two other hoppers.
When done, it activates a SEAL for 2 seconds to advance a heated ram
that seals the package. After that, the DONE output is turned on until the
PRESENT sensor turns off. Write the ladder logic for this process.

15. i). Write a program that will turn on a flashing light for the first 180
seconds after a PLC is
turned on. The light should flash for half a second on and half a second
off.
(Doesn’t use limit or any data compare instructions and use only two
timers)
ii).Write ladder logic to reset an RTO retentive timer (T4:0) without using
the RES instruction.

16. i). We are designing a movie theater marquee, and they want the
traditional flashing lights.
The lights have been connected to the outputs of the PLC from O:
001/00 to O: 001/17 When the PLC is turned, every second light should
be on. Every half second the lights should reverse. The result will be
that in one second two lights side-by-side will be on half a second each.
ii) Design ladder logic that uses normal timers and counters to measure
times of 50.0 days.

17. We are developing a safety system (using a PLC-5) for a large

industrial press. The press is activated by turning on the compressor
power relay (R, connected to O:013/05). After R has been on for 30
seconds the press can be activated to move (P connected to O:013/06).
The delay is needed for pressure to build up. After the press has been
activated (with P) the system must be shut down (R and P off), and then
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 the cycle may begin again. For safety, there is a sensor that detects when
a worker is inside the press (S, connected to I:011/02), which must be off
before the press can be activated. There is also a button that must be
pushed 5 times (B, connected to I:011/01) before the press cycle can
begin. If at any time the worker enters the press (and S becomes active)
the press will be shut down (P and R turned off). Develop the ladder logic.
State all assumptions, and show all work.

18. The following figure represents an industrial operation of thermal processing of metals,
the machine hardens the metal in the shape of a steel ring. the hardening process is done by
heating the steel ring to a very high temperature, then it goes through a sudden cooling. So
the piece we want to harden is heated by passing very high currents through a coil that heats
the piece, then we cool it very quickly by sending cold water through the holes in each side.

This process is summarized as following:

xi. When the main push button is pressed, the system is activated.
xii. The piece is put in its place (on spindle)

xiii. Pressing two push buttons (the left and the right) to start the process.

xiv. The system can be deactivated (off) completely and quickly by OFF push button.

xv. The piece goes from down to above through an air-cylinder that works by a
Solenoid valve. it comes back after the valve has been disconnected by the Spring
or by the falling weight (gravity). this will not happen, of course, unless the piece
12
 exists, which is known using the sensor LSPP which detects the piece (i.e.
working piece).

xvi. The spindle activates the switch LSU when it reached it.

xvii. Then the heat will start for only 10 seconds.

xviii. After that, cooling starts and lasts only 10 seconds.

xix. The piece returns to the bottom by the gravity, after the Solenoid valve has been
disconnected. Then the LSU returns to the normal state – normally open (NO) –
after the piece has gone down.

xx. The system after that will be in a RESET state.

xxi. Then we could put a new piece and repeat the whole process.

1. Tony loves garlic-infused olive oil, and so he decides to build an automated process for
mixing large batches of it:

Develop a PLC program to perform the following sequence, each step lasting 5 seconds,
and also develop a HMI screen to indicate the its OUTPUT states.

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Inputs
• Start pushbutton (momentary NO) – press to begin the mixing sequence
• Stop pushbutton (momentary NO) – press to halt (freeze) the mixing sequence
• Reset pushbutton (momentary NO) – press to reset the sequence to the first step
Outputs
• Oil valve – energize to open up the oil valve, admitting oil into the mixing tank
• Mixer motor – energize to turn the mixer paddle
• Garlic feed – energize to add ground garlic to the mixing tank via the screw conveyor
• Drain valve – energize to open up the valve and drain the mixing tank

2. Develop a ladder program and HMI screen for the following case:
 There are two conveyers, each is fitted with sensors to count the input and output of parts
entering and leaving the conveyer, for that a factory need a three indicating lights, and
the condition is
a) Compare the two conveyors input
b) The inputs of both conveyors are equal-Turn ON green light.
C) The inputs of both conveyors are not equal -Turn ON RED light
 Construct a ladder program and develop HMI screen for the given case
Simplify the following Boolean functions
a) F=wx’+y’z’+w’yz’
b) F=AB’CD’+A’BCD+AB’C’D+A’BC’D

3. Develop and execute ladder program for two double acting cylinders to do the following
sequence of operation A+B+B-A-. by using Micrologix 1200 PLC.(Wiring connection
should be in sinking concept)

4. Conduct suitable Experiment for Level control by using Micrologix 1000 PLC. Indicate the
I/O status and water level in HMI screen.

5. Construct an electromagnetic circuit with two double acting cylinders to do the following
sequence of operation A+(5 sec time delay) B+ (7 sec time delay) B- (10 sec time delay) A-
( 5 sec time delay) repeat the sequence for 7 times by using PLC.
 Simulation to be done by using RS Logix 500 Emulate
 Develop a HMI screen for outputs, timers and counters.

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6. Develop and execute ladder program for two double acting cylinders and push button so that
when the button is pressed cylinder A should extend and then cylinder B should extend when
the cylinder B reaches its end positions both cylinders should retract the same time.
Develop a HMI Screen for the above case

7. Construct a traffic light sequence for a two road junction with pedestrian crossing.
 Timers and counters can use to develop program.
 Do not use any data compare, math and logical instructions
 Develop a HMI Screen for the above case

8. Develop a ladder program and HMI screen for the following case:
To perform the Math operation for the case study as shown in figure and to calculate the
following.
 To calculate the total no of balls that is falling in basket
 Assume the total no of balls are 50
 Monitor the balls that falling in the basket it should not exceed 50. If exceed more than
50 turn ON Electric Alarm.

9. Construct a PLC program for the sequence A+B+ (120 sec delay)A-B-(60 sec delay)
Repeat the sequence continuously. It should stop when STOP push button is pressed.
Timers and counters can use to develop program.
Do not use any data compare, math and logical instructions
Develop a HMI Screen for the above case

10. Develop a suitable ladder program for Temperature control process

 There is RTD used.
 Signal conditioning output voltage is 3.075 VDC at temperature 57 ̊ C
 Find out the signal conditioning output voltage of following temperature range 33.02 ̊ C,
40 ̊ C, 49.85 ̊ C, 55.09 ̊ C and store the values in any register.
 The output voltages and temperatures are should be display in HMI screen.

11. Develop a ladder program for Flow control process.

 Implement by using Micrologix 1400 PLC.
 The valve should open in the range of pressure 0.5 bar to 1.7 bar.
 Analog input of PLC is 0-5VDC. It should not exceed +5VDC

12. Suppose you wish to control the following robot’s movement.

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 The kind of robot is seen in many automated factories. As is apparent from the figure, this robot
picks up a work being carried on conveyor A, and places it on conveyor B.

13. Develop a ladder diagram for following operations and conditions:

Looking at the above figure closely will disclose that the robot performs one operation at a time
when a given condition is met. Let’s analyze these operations and conditions.
i. When the start the push button is pressed, the robot rotates its arm clockwise.
ii. When the robot arm has moved to the position of the work in conveyor A, the arm grasps
the work.
iii. When the arm has grasped the work, it rotates counter clockwise.
iv. When the arm has rotated to the position of the conveyor B, it release the work.

14. 10 parts at a time are stamped on a machine. The program cycle is started by means of a
push button S1. The proximity switch B7 signals "Part in magazine". A part is fed towards
the machine by means of a cylinder 1.0 and clamped. It is then stamped via cylinder 2.0, and
subsequently ejected by means of an ejecting cylinder 3.0. The clamping cylinder 1.0
operates via a double solenoid valve with two coils Y1 (clamping) and Y2 (unclamping).
Cylinders 2.0 and 3.0 are powered by spring-return solenoid valves with the coils Y3 and Y4.
The cylinder positions are monitored by means of the proximity switches B1 to B6.

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  Develop a ladder diagram for the above case, Develop a HMI screen for the I/Os of the
above case and control the program via HMI screen.

15. A work piece is to be clamped by activating the start button S1. When the work piece is
clamped by cylinder 1.0, cylinder 2.0 extends and embosses the work piece. Since the work
piece requires time to cool down, it remains clamped for a period of 3 seconds. This time is
started with the advancing of cylinder 1.0.

 Develop a ladder diagram for the above case.

 Develop a HMI screen for the I/Os of the above case and control the program via HMI
screen.

16. A new printing station will add a logo to parts as they travel along an
assembly line. When a part arrives a ‘part’ sensor will detect it. After
this the ‘clamp’ output is turned on for 10 seconds to hold the part
during the operation. For the first 2 seconds the part is being held a
‘spray’ output will be turned on to apply the thermoset ink. For the last
8 seconds a ‘heat’ output will be turned on to cure the ink. After this

17
 the part is released and allowed to continue along the line. Write the
ladder logic for this process.

17. Conduct suitable Experiment for Networking of PLC.

Consider the following for conducting experiment:
 Develop a single HMI screen to control (Start & stop) the PLCs which
connected within the network.
 If any timers and counters used in program, the timers and counters acc. values
should be display in HMI screen.

18. Develop a ladder program for following case:

This morning you received a call from Mr. Ian M. Daasprate at the
Old Fashioned Widget Company. In the past when they built a new
machine they would used punched paper cards for control, but their
supplier of punched paper readers went out of business in 1972 and
they have decided to try using PLCs this time. He explains that the
machine will dip wooden parts in varnish for 2 seconds, and then apply
heat for 5 minutes to dry the coat, after this they are manually
removed from the machine, and a new part is put in. They are also
considering a premium line of parts that would call for a dip time of 30
seconds, and a drying time of 10 minutes. He then refers you to the
project manager, Ann Nooyed. You call Ann and she explains how the
machine should operate. There should be start and stop buttons. The
start button will be pressed when the new part has been loaded, and is
ready to be coated. A light should be mounted to indicate when the
machine is in operation. The part is mounted on a wheel that is rotated
by a motor. To dip the part, the motor is turned on until a switch is
closed. To remove the part from the dipping bath the motor is turned
on until a second switch is closed. If the motor to rotate the wheel is on
for more that 10 seconds before hitting a switch, the machine should
be turned off, and a fault light turned on. The fault condition will be
cleared by manually setting the machine back to its initial state, and
hitting the start button twice. If the part has been dipped and dried
properly, then a done light should be lit. To select a premium product
you will use an input switch that needs to be pushed before the start
button is pushed. She closes by saying she will be going on vacation
and you need to have it done before she returns.
You hang up the phone and, after a bit of thought, decide to use the
following outputs and inputs,
INPUTS: I/1 - start push button, I/2 - stop button, I/3 - premium part
push button, I/4 - switch - part is in bath on wheel, I/5 - switch - part is
out of bath on wheel
OUTPUTS: O/1 - start button, O/2 - in operation, O/3 - fault light, O/4 -
part done light
O/5 - motor on , O/6 - heater power supply

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1. Develop a ladder diagram and HMI screen for the following case:
The drill on a drilling unit is monitored by means of a drill breakage sensor (B1). If the drill is
broken, the sensor interrupts the circuit. A buzzer (H1) is to sound in this event. The buzzer can
only be switched off via push button S1.

2. Develop a ladder program and HMI screen for the following:

A device that will count parts as they pass by an inspection stand. The
sensing device for the PLC is a switch that will close each time a part passes.
This switch is connected to IN1 of the PLC. A reset switch, IN2, is also
connected to the PLC to allow the operator to manually reset the counter.
After 15 parts have passed the inspection stand, the PLC is to reset the
counter to again begin counting parts and turn on a light which must stay on
until reset by a second reset switch connected to IN3. The output from the
PLC that lights the light is OUT1.

3. We try a simple blending of water and acid in a container where we only have three level
sensors(L1,L2, and L3) and two liquids flowing in through two solenoid valves, solenoid a(water
control) and solenoid b(acid control)and draining out through solenoid c(blend outflow).The batch is
to be controlled by timer. After required level of blend is sensed (by L1) the mixer runs for 3 minutes
by the motor. They are mixed in ratio of 3:2. The process initiates with the drain valve open, water
and acid valves closed, mixer motor is off, and the tank is empty.

 Develop a ladder diagram for the above case, Develop a HMI screen for the I/Os of the
above case and control the program via HMI screen.
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 4. Construct a PLC program for the sequence A+B+ (90 sec delay) B-A-(1 min).
 Repeat the sequence for 9 times and then it should stop.
 Don’t use any data compare instructions, math instruction and logical instruction.
 You should use only timers and counters.
 Develop a HMI Screen for the above case
.
5. Construct an electromagnetic circuit with a single acting cylinder to extend and retract
continuously with help of limit switch by using Micrologix 1200 PLC.
 Simulation to be done by using RS Logix 500 Emulate
 Calculate & Display, how many times the cylinder actuated?
 Develop a HMI screen for display the value of counter.
 Develop a HMI screen for Start and stop push buttons and control the program via HMI
screen.

6. Conduct a suitable experiment for water level control by using Micrologix 1000 PLC.
Develop a HMI Screen for the above case

7. Construct a traffic light sequence for a three road junction with pedestrian crossing.
 Timers and counters can use to develop program.
 Do not use any data compare, math and logical instructions
 Implement the program by using Micrologix 1000PLC.
 Wiring connection should be in sourcing concept.

8. Develop a ladder program and single HMI screen for the following case:
i. There are two conveyers, each is fitted with sensors to count the input and output of
parts entering and leaving the conveyer, for that a factory need a three indicating
lights, and the condition is
a) Compare the two conveyors (A, B) output
b) A>B-Turn ON green light.
c) A<B -Turn ON RED light
ii. There are two conveyers, each is fitted with sensors to count the input and output of
parts entering and leaving the conveyer, for that a factory need a three indicating
lights, and the condition is
a) Add the two conveyors (A, B) output
b) (A+B) =10 -Turn ON green light.
c) A+B) <10 -Turn ON RED light

9. A temperature control system is being developed to control the water flow

rate for cooling a mold set. Unfortunately the sensor in the dies doesn’t allow
us to measure the temperature. But it does provide a set of bimetallic
contacts that close when the die is above 110C. Luckily a Variable Frequency
Drive (VFD) is available for controlling the flow rate of the water. The control
scheme will increase the water flow rate when the die temperature input,
HOT, is active. When the HOT input if off the flow rate will be decreased, until
the flow rate is zero. In other words, when the HOT input is on, a timer will
start. The time accumulated, DELAY, will be proportional to a voltage output
to control the VFD. If the HOT sensors turns off the DELAY value will be
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 decreased until it has a value of zero. Write the ladder logic for this
controller.
(Develop a HMI Screen for the above case)

10. Write ladder logic to calculate the average of the values from thickness
[0] to thickness [99]. The operation should start after a momentary
contact push button A is pushed. The result should be stored in
’thickness_avg’. If button B is pushed, all operations should be complete
in a single scan. Otherwise, only ten values will be calculated each scan.
(Note: this means that it will take 10 scans to complete the calculation if A
is pushed.
(Develop a HMI Screen for the above case)

11. In dangerous processes it is common to use two palm buttons that

require a operator to use both hands to start a process (this keeps hands
out of presses, etc.). To develop this there are two inputs (P1 and P2) that
must both be turned on within 0.25s of each other before a machine cycle
may begin.

Develop a ladder diagram to control a process that has a start (START)

and stop (STOP) button for the power. After the power is on the palm
buttons (P1 and P2) may be used as described above to start a cycle. The
cycle will consist of turning on an output (MOVE) for 2 seconds. After the
press has been cycled 1000 times the press power should turn off and an
output (LIGHT) should go on.

(Develop a HMI Screen for the above case)

12. Use a state diagram to design a parking gate controller.

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 -the gate will be raised by one output and lowered by another. If the gate gets stuck an over
current detector will make a PLC input true. If this is the case the gate should reverse and the
light should be turned on indefinitely.
- if a valid keycard is entered a PLC input will be true. The gate is to rise and stay open for 10
seconds.
- when a car is over the car detector a PLC input will go true. The gate is to open while this
detector is active. If it is active for more that 30 seconds the light should also turn on until the
gate closes. (Develop a HMI Screen for the above case)

13. Conduct a suitable experiment for speed control of DC motor and also develop a HMI screen
for the experiment.
(Develop a HMI Screen for the above case)

14. Consider the following to conduct a Networking of PLC experiment:

 There are two PLCs(PLC 1 & PLC2), it connected via RS 232 and Ethernet respectably.
 Develop a single HMI screen for both PLCs.
For PLC 1, develop a ladder diagram for following:
To perform the Math operation for the case study as shown in figure and to calculate the
following.
a) to calculate the total no of balls that is falling in both baskets(A and B)
b) if the white ball fall in the basket A-Turn ON Electric alarm
c) if the block ball fall in the basket A t-Turn ON Green light
For PLC 2, develop a ladder diagram for following:
To perform the Math operation for the case study as shown in figure and to calculate the
following.
a) To calculate the total no of balls that is falling in basket
b) Assume the total no of balls are 50
c) Monitor the balls that falling in the basket it should not exceed 50. If exceed more than
50 turn ON Electric Alarm.

15. Conduct suitable Experiment for pressure measurement by using PLC in the range of
0.25 to 1 bar. Develop a HMI screen to display the various parameters like pressure, input
and output voltages, PLC digital count etc.

16. Develop a ladder program and Develop HMI screen for the following case:
A mixing plant permits a selection between two bulk materials per selector switch (S2).
In switch position 1 (S2 = 0 signal), bulk material A reaches a mixing container, if push
button S1 is actuated simultaneously.
Similarly, bulk material is conveyed, if selector switch S2 is in position 2 (S2 = 1 signal)
and push button S1 is actuated. Silo A is opened via cylinder 1.0 (solenoid valve Y1), Silo B
via cylinder 2.0 (solenoid valve Y2).

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17. A conveyor line is to be controlled with either a variable frequency drive, or a brushless
servo motor. Workers will place boxes on the inlet side of the conveyor; these will be
detected with a ‘box present’ sensor. The box position is also detected with an ultrasonic
sensor with a range from 10cm to 1m. When present, boxes on the conveyor will be moved
until they are 55cm from the sensor. Once in place, the system will stop until the box is
removed. After this, the process can begin again when a new box is detected. Design all of
the required ladder logic for the process.
(Develop a HMI Screen for the above case)

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