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PLC Programming and Problem Solving

The document outlines the IENG 360 Production Automation Lab, focusing on PLC programming and problem-solving techniques. It covers various components such as digital and analog switches, sensors, actuators, and the differences between PLCs and microcontrollers. Additionally, it provides a problem-solving example involving a ladder diagram for controlling a piston using an Allen Bradley SLC500 PLC.

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Mathabah Omer
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9 views27 pages

PLC Programming and Problem Solving

The document outlines the IENG 360 Production Automation Lab, focusing on PLC programming and problem-solving techniques. It covers various components such as digital and analog switches, sensors, actuators, and the differences between PLCs and microcontrollers. Additionally, it provides a problem-solving example involving a ladder diagram for controlling a piston using an Allen Bradley SLC500 PLC.

Uploaded by

Mathabah Omer
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
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IENG 360 Production Automation Lab

PLC Programming and problem solving

Eng. Ayman Salem

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Electronics type
• Digital gates
• Limit switch, push-button,
• Relays, Transistor

• Analog switches
>
- • Potentiometer

• Sensors
• Photovoltaic, TOF range, ultrasonic
-

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Continue
=
• Actuators
• DC motor, solenoid valve
--

• Microcontroller shields
• CPUs, MCUs, GPUs

• Audio or radio transmitters


• Buzzer, Speaker, Bluetooth

• Telecommunication modules
• GSM, GPS
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Analog Vs. Digital Signals
• Example: Wall switches for room light control

On/Off only

Variable
input/output
control

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How to Control?
• Programmable Logic Controller (PLC)
• For industrial scale automation.
• Expensive and reliable,
• Easy to program and troubleshoot,
• Ready made circuits and codes
• Big memory, expandable module interfaces

• Microcontrollers (e.g. Arduino & Raspberry Pi)


• For products and small projects scale
• Cheap,
• Difficult to code from scratch,
• Complex to build circuits,
• Non-expandable, limited inputs/outputs.

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PLC
• It is similar to a computer,

• Uses Ladder logic programming


using simple applications.

• PLC manufacturers provide the app


and built-in programs for each
module installed.

• Watch:
• https://www.youtube.com/watch?v
=PbAGl_mv5XI
• https://www.youtube.com/watch?v
=nYr8Q21nG0k

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Arduino MCU & PCB board

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Arduino Software

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Pneumatic Sys. Hardware
Components:
• Air compressor
• Pneumatic Flow Control Valve (FCV)
• 2 off 5/2 Directional Control Valve (DCV), 1 off 3/2 Directional
Control Valve (DCV)
• 2 off double acting pneumatic cylinder (solenoid/solenoid) 1
off single acting pneumatics cylinder (solenoid/spring)
• 4 off limit switch & 2 off push button.

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Hydraulic Pneumatic
Power

Applications • Lift cars using a hydraulic lift • Conveyor systems in pharmaceutical and food industries
• Hydraulic braking system in cars • Precision drills used by dentists
• Wing flaps on aircraft • Manufacturing and assembly lines
• Turbines and Dams • Elevators and train door

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Valve actuation symbols

3
Control of a double-acting cylinder with solenoid, (a) not activated, (b) activated.

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Overview
Input variables (I:) Output variables (O:)

Sensors Processing Actuators


PLC Ladder-logic Pumps, motor, etc.
Virtual variables (B:)
States, timer delay,
Switches functions, etc.
LEDs,
Limit, power, etc.
Speakers

Etc. Etc.

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Understand Ladder Symbols
Counter
Rung (rail) N.O. & N.C. contacts (Preset, Accum, Reset)

Sub-rung Coil (output) Timer

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2
Problem Solving
• Construct, test and verify a ladder diagram that can perform the motions described below using
MTK kit and Allen Bradley SLC500 PLC.
• Press “Start Button” to start the process.
• Move Piston A from point (a) to point (b)
• Move Piston A back from point (b) to point (a)
• Motion (2) and Motion (3) should be repeated five times/cycles.
• Stop Piston A,
• Press the start button to re-start the process again.

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Solution Step 1: Wiring
1
• Notes:
• Always wire the circuit before constructing ladder program.
• Use states (B:) to simplify the logic
• Always connect switches as normally-open (NO) for safety.
• Can you guess when to use normally-closed (NC) switches?
• Notation assignment (variable:module/Bit)
2
Component Variable type (I/O/B) Module/Bit

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Continue: Wiring diagram

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Solution Step 2: Sequence Table
• Press “Start Button” to start the process.
• Move Piston A from point (a) to point (b)
• Move Piston A back from point (b) to point (a)
• Motion (2) and Motion (3) should be repeated five times/cycles.
• Stop Piston A,
• Press the start button to re-start the process again.

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Solution Step 3: Construct Ladder Diagram

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