Scribd
Upload
8 views5 pages

Exp 7

The document outlines an experiment focused on developing a ladder diagram and programming a PLC for a Bottle Filling Plant using a Micrologix 1000 PLC. It details the theory behind PLCs, their advantages, and the specific steps required to implement the control system, including the sequence of operations for the bottle filling process. The procedure concludes with the simulation of the PLC ladder diagram for the Bottle Filling Plant model.

Uploaded by

adityathombare26
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
8 views5 pages

Exp 7

The document outlines an experiment focused on developing a ladder diagram and programming a PLC for a Bottle Filling Plant using a Micrologix 1000 PLC. It details the theory behind PLCs, their advantages, and the specific steps required to implement the control system, including the sequence of operations for the bottle filling process. The procedure concludes with the simulation of the PLC ladder diagram for the Bottle Filling Plant model.

Uploaded by

adityathombare26
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 5

Experiment No.

07

Title: Development of ladder diagram / programming PLC


Aim: To develop ladder diagram and to program PLC Bottle Filling Plant.
Apparatus: Micrologix 1000 PLC with hand held programmer,
Control panel with simulation switches and indicator lamp,
Bottle Filling Plant Trainer Model.
Theory:
Programmable Logic Controllers (PLC):
Programmable Logic Controller abbreviated to PLC has long been used in the
industrial automation platform. In late 60's PLCs were introduced. The primary
reason for designing such a device was to facilitate communication capability and
to replace the sluggish relay based machine control systems. The major application
of PLC is to replace the real world relays. The PLCs have been applied for factory
automation, machine control, process control, instrumentation, data acquisition and
control and many manufacturing systems. The PLC originated to replace traditional
relay-based control implementation. It is considered as the first generation of
computerized version of process control systems. The PLC based implementation is
applicable where sequential logic is necessary. As per requirement, the PLC has to
be programmed. The desired operation is achieved when the program is executed.
The PLC is programmed through a method called ladder logic technique, which
means that sequences of logical actions must be established, interlinked in a
synchronous and timely manner. The PLC samples the inputs and depending upon
the state provides output in terms of ON or OFF. The basic blocks of the PLC are:
• Central Processing Unit
• Memory
• Input module
• Output module
Fundamentally, the PLC can be thought of as a cabinet consists of thousands of
relays, counters, timers and memory cells. The relays are categorized under three
headings, namely field relays, interior relays and output relays. The field relays are
realized by the use of transistors and thus physically exist. They are connected to the
field devices such as sensors, switches etc. The signals from the outside world are
fed to the field relays. The output relay are responsible to send on/off signal to the
outside world such as solenoid, LED, gizmo, etc. They are also made up of
ansistors:1 The interior relays, counters and timers are realized by simulationlThe
register bits are used to realize the simulation. Some of the interior relays are ON

The building blocks of a typical PLC:


c

The PLC works by repeatedly looking into the program. This repetition cycle has
three steps, namely sense, decide and act. During the sense phase of the cycle, the PLC
looks the current state of the process under its control in terms of looking at each field
devices to conclude if it is ON or OFF state. Indeed the status of the first input, second
input, third input and so on is sensed cyclically. Then it transfers the sensed data to the
storage cells and records. The stored data are used during the next step during which
the PLC executes the program. The programs are executed one instruction at a time,
sequentially. In response the execution of the program it turns ON or OFF the outputs
of the corresponding inputs. It then stores the results of the execution for subsequent
use and at the end the PLC always updates the status of the outputs. Thus it updates
the outputs based on which inputs were ON or OFF during the first step and the results
of executing the program during the second step, Once the final step is over the PLC
goes back to step one and repeats the steps endlessly. One scan time is defined as the
time it takes to execute the 3 steps listed above.
Fundamentally, the following processes are involved in order to implement a PLC
based process control system. Firstly the components used in a traditional relay-based
control system are translated into symbols that the PLC understands. All the devices
are assigned with unique addresses. Various addressing schemes are usually used.
There is a requirement to create a ladder diagram because a PLC does not understand
the schematic diagram. In the final process the schematic diagram is converted into a
logical sequence of events. Most PLCs have software, which converts ladder diagrams
into code. The PLCs have been popular because of their advantages as follows.
Advantages of PLC:
1. PLC can work in rugged environment and can work in the factory floor.
2. They can operate in the adverse condition of the factory floor.
3. They can withstand vibrations, interference, transients, noise etc.
4. They can work from zero degrees centigrade to above forty degrees centigrade:
5. PLC can replace hundreds of relays and occupy significantly less space.
6. The circuit logic can be easily altered without rewiring.
7. It has no moving parts or contacts to wear out.
8. The down time is less than the relay circuit.
9. The implementation is flexible and scalable.
10. Faster response time
Problem Statement:
For the Bottle filling system, develop a PLC ladder diagram
and implement the same. The sequence of operation is
1) Initiation: Start the level control system for 60 sec. ( Initial refill of the tank)
2) Running: a) Start the bottle conveyor.
b) When the bottle is in position stop the conveyor & open the
valve.
c) When bottle is full, close the valve.
d) Go to step a) and repeat.
Specifications of the Micrologix 1000 PLC:
Broad input and output specifications make Micrologix a highly flexible solution.
120 V AC outputs
Sink / Source selectable 24 VDC inputs
Adjustable 24 VDC input filters with 9 settings
120 VAC, 3.5A relay outputs
Two isolated relay outputs per units minimum.
High current carrying capacity for both relay and 24 VDC outputs.
The Micrologix 1000 is one of the fastest micro PLCs .Available execution
time, for typical introduction program is only 1.56 msec.
Throughput- the time required to sense an input and energize a corresponding
output is a mere 85 msec. for the same 500 instruction program.
Micrologix has a large l k user memory capacity and makes the most of it.
Data elements:
512 bits, 40 timers, 32 counters , 16 control files, 105
integer files and 33 diagnostic states,
I/O listing is an follows.
Inputs
I/10 -Start
I/11 -Stop
I/1 -Bottle in position
I/2 -Bottle full
Outputs
O/1 -Conveyor motor
O/2 -Valve -
Procedure:
1) Connect the hand-held programmer with the Micrologix1000 PLC &
switch ON the power.
2) Select RPRG mode.
3) Program the ladder diagram (fig2)
4) Change to RUN mode,
5) Verify the sequence of operations of the Bottle filling system.
Conclusion
The PLC ladder diagram is simulated for the Bottle Filling Plant model

You might also like