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PLC Lab

The document discusses the role and functionality of Programmable Logic Controllers (PLCs) in industrial automation, detailing their configuration, programming languages, and application in a ball sorting mechanism experiment using the SIEMENS SIMATIC S7-1200. It emphasizes the importance of understanding PLCs for students as they prepare for industry challenges. The conclusion suggests that PLC education should be expanded into a dedicated course to enhance student readiness for real-world applications.

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Asmaa A-Elghany
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19 views21 pages

PLC Lab

The document discusses the role and functionality of Programmable Logic Controllers (PLCs) in industrial automation, detailing their configuration, programming languages, and application in a ball sorting mechanism experiment using the SIEMENS SIMATIC S7-1200. It emphasizes the importance of understanding PLCs for students as they prepare for industry challenges. The conclusion suggests that PLC education should be expanded into a dedicated course to enhance student readiness for real-world applications.

Uploaded by

Asmaa A-Elghany
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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UNIVERSITI KUALA LUMPUR

BRITISH MALAYSIAN INSTITUTE

PROGRAMMABLE LOGIC CONTROLLER AND


APPLICATION
BPB 31403
L01-B01

LAB 2

LECTURER’S NAME:
SIR SAHARUDDIN BIN OTHMAN

PRODUCED BY:
HUSNI ZULFIKRI BIN ZURAIDI
51211217100
Introduction
Programmable logic controllers (PLCs) have been an integral part of factory automation and
industrial process control for decades. PLCs control a wide array of applications from simple
lighting functions to environmental systems to chemical processing plants. These systems
perform many functions, providing a variety of analog and digital input and output interfaces,
signal processing, data conversion, and various communication protocols. All of the PLC's
components and functions are centered on the controller, which is programmed for a specific
task. The basic PLC module must be sufficiently flexible and configurable to meet the
diverse needs of different factories and applications. Input stimuli (either analog or digital)
are received from machines, sensors, or process events in the form of voltage or current. The
PLC must accurately interpret and convert the stimulus for the CPU which, in turn, defines a
set of instructions to the output systems that control actuators on the factory floor or in
another industrial environment.
PLC take up less space, perform more complex tasks and are more customizable than
the mechanical technologies they have replaced. They are known for their ability to operate
continuously without maintenance and have had a great impact on digitizing a great many
industries, particularly manufacturing. The first PLC, for example, was invented by Dick
Morley in 1969 for General Motors and performed uninterrupted for 20 years before being
retired.

PLC configuration should be considered during flowcharting and logic sequencing.


The PLC’s configuration defines which I/O modules will be used with which types of I/O
signals, as well as where the modules will be located in the local or remote rack enclosures.
The modules’ locations determine the I/O addresses that will be used in the control program.
During system configuration, the user should consider the following: possible future
expansions; special I/O modules, such as fast-response or wire fault inputs; and the placement
of interfaces within a rack (all AC I/O together, all DC and low-level analog I/O together,
etc.).

Five programming languages are used to code PLCs, as specified by International


Electro technical Commission (IEC) 61131. They are Ladder Logic, Function Block Diagram
(FBD), Structured Text (ST), Instruction List (IL) and Sequential Function Chart (SFC).
Should significant code changes be required and the PLC's memory is embedded, the
controller can be recoded in place. When the PLC's memory is not embedded on the circuit
board and significant code changes are required, the memory can be removed from an
exterior slot on the PLC and replaced without requiring the assistance of a programmer on
site.
Basic PLC structure
Experimental Set-up

Simatic S7-1200
Input device Address Output device Address number
number
Start push button I0.0 Relay Q0.1

Emergency push I0.1 Meter QW80


button
Reference weight IW64
Actual weight IW66

Table 1:Input/Output devices


Flow chart
Timing diagram

Ladder diagram
Wiring diagram
Ladder diagram and compilation of results
1) System off

2) System on
3) Ball sensor on

4) Top cylinder on
5) Timer counting

6) Colour sensor on
7) Bottom cylinder on

8) Pusher on

9) Green counter in range less than 40 ON for white ball


10) Green light ON for white ball

11) Amber counter in range 40 t0 49 ON for white ball


12) Amber light ON

13) Red counter triggered when container is full for white ball
14) Red light ON for white ball

15) Green counter in range less than 40 ON for black ball


16) Green light ON for black ball

17) Amber counter in range 40 t0 49 ON for black ball


18) Amber light ON for black ball

19) Red counter triggered when container is full for black ball
20) Red light ON for black ball

Analysis and Discussion


For this laboratory 2, students need to design an application about ball sorter
mechanism. So, by using SIEMENS SIMATIC S7-1200 they need to produce flow
chart, ladder diagram and timing diagram to fulfill the requirement of the experiment
to get the correct simulation for the system. It quite easy task because students just
need to sort among white and black ball only. But, for them who not familiar with this
application, it not become very easy actually because they need to do more research
about this application.
By using TIA PORTAL of SIEMENS SIMATIC S7-1200, the configuration
need to settle first before proceed to ladder diagram design. After that, the ladder
diagram was design start from the system off until all the ball was sort by same colour
and same value. In this application, students learn a lot of instruction such as set reset,
CTUD, in range, out range and how to use the %M as memory because it not include
in input or output in the application.
After settle all the ladder diagram, students proceed to set-up hardware, but for
this experiment, the hardware needed was not enough so they just need to draw wiring
diagram of the application with the correct connection. From the wiring diagram, they
actually learn and can imagined how the system operated from start to end. If the
ladder diagram produced was right, the system will running smoothly without any
problem.
Conclusion and Recommendations

As a conclusion, from this experiment, students learnt a lot of new instruction and know how
to use it compare with the experiment doing before. This lab also make the students think and
imagined more how the application works by creating their flow chart and from there they
can produced ladder diagram to completed the experiment.

Also by learning this course was very good exposure for students because one day,
they will faced the tough industry that used all this kind of system. So, if now they got the
basic of this system, it will become easier for them to join the industry.

As recommendations, PLC was a very great application and used from long time ago
until now but with different technology. So, it was very recommended if this subject just not
a subject but it need to be a new course at university to be learn. University also will
collaborate with any company that runs this system as education collaboration, from that both
side will got their benefit.
References
1. http://isd-soft.com/tech_blog/basics-siemens-plcs-programming-simatic-
step7/
2. http://www.ieec.uned.es/investigacion/Dipseil/PAC/archivos/
introtoplcs_SUPER.pdf
3. https://w3.siemens.com/mcms/topics/en/simatic/pages/default.aspx
SIMATIC websites

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