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OBJECTIVE
LINEAR CYLINDERS
➨ Single-acting Cylinder
➨ Double-acting
Cylinder
ROTARY CYLINDERS
Sprin
g
Vent
Connectio
n
Pisto Seal
n
Single Acting Cylinders
If compressed air is
supplied, air hits the piston
surface and the piston rod
moves out. When air is
released, the return spring
moves the piston to its
initial position.
Single acting cylinders do
work in one way, therefore
they are ideal for
tensioning, ejecting,
compressing etc.
Operation of Single Acting Cylinders
Operation of Single Acting Cylinders
Cushionin
Seal
g sleeves
s
Non-return valve
Cushioning adjustment
Operation of Double Acting Cylinders
with Air Cushioning
Operation of Double Acting Cylinders
with Air Cushioning
Operation of Double Acting Cylinders
with Air Cushioning
Operation of Double Acting Cylinders
with Air Cushioning
Operation of Double Acting Cylinders
with Air Cushioning
Operation of Double Acting Cylinders
with Air Cushioning
Operation of Double Acting Cylinders
with Air Cushioning
Operation of Double Acting Cylinders
with Air Cushioning
Operation of Double Acting Cylinders
with Air Cushioning
Operation of Double Acting Cylinders
with Air Cushioning
Operation of Double Acting Cylinders
with Air Cushioning
Operation of Double Acting Cylinders
with Air Cushioning
Operation of Double Acting Cylinders
with Air Cushioning
Operation of Double Acting Cylinders
with Air Cushioning
Operation of Double Acting Cylinders
with Air Cushioning
Operation of Double Acting Cylinders
with Air Cushioning
Operation of Double Acting Cylinders
with Air Cushioning
PNEUMATIC VALVES
FUNCTIONS :
➨ regulate pressure
Principles: AI MS :
❍ The new standard takes into account ● Uniform standard program languages
as many as possible aspects of
● Manufacturer-independent
manufacturing and application of
● Open interfaces in the program systems
PLC systems.
Ideally, download of programs to
❍ The manufacturers must conform
different hardware systems
with the instructions regarding the
technical requirements of a PLC as
well as the programming.
❍ Any deviations must be fully
documented for the user.
Selecting a PLC
Number of I/O’s
Kind of signals : digital or analog
Fieldbus system or standalone
Modular or compact
Operating voltage
Positive or negative triggerred input
Relay or transistor output
Operating systems
System
Components
Program
Sensorics Actorics
PLC SYSTEM
INPUTS PROCESSOR
OUTPUTS
The PLC System
Acknowledging
Limit switches
Sensors
Pushbuttons
Relays
Transmitters
Signal Generators
Input Module : Functions
Final control
elements
Relays
Electrical loads
Solenoid coils
Lamps
Indicators
Alarms / buzzers
Construction of a PLC
Communication
Processor
Power
Output
Input
Input
supply
FEC34 PLC in
Distribution
Station
FESTO
DIDACTIC
✲ Registers : 64 (RAM or
✲ Timers : 32 EPROM)
✲ Counters : 16 ✲ Delay Time : 5ms - input
FESTO FEC-20-DC
✲ Operating Voltage ✲ Program Structure : 8 User Program
24 VDC Connection
IPC-CPU
AS-i Master
Serial Interface
AS-i cable
FESTO PLC : Optimum Control
Festo IPC
- the allrounder
Sample
setup
0 0
PB 1 1
2 IF PB 2
LAMP
3 THEN SET Y1 3
4 IF N PB 4
5 THEN RESET Y1 5
6 6
7 7
+ -
FESTO SOFTWARE TOOL
( FST )
Ladder Diagram
1. Instruction
2. Instruction
3. Instruction
4. Instruction
Program
Last Instruction
Ladder Diagram
Neutral
Power
Rail Rail Ladder diagram is a drawing
S1 showing all the switches,
RUNG 1
CR1 sensors, motors, valves, and
S2 relays that are used in the
control circuit.
RUNG 2
S2 S3 CR2
0 0
PB 1 1
2 IF PB 2
LAMP
3 THEN SET Y1 3
4 IF N PB 4
5 THEN RESET Y1 5
6 6
7 7
+ -
Sample
setup
0 0
PB 1 1
2 IF PB 2
LAMP
3 THEN SET Y1 3
4 IF N PB 4
5 THEN RESET Y1 5
6 6
7 7
+ -
Ladder Diagram
Executive Part
Conditional Part
– Language
Elements
- inputs
normally closed
normally open
- outputs
Coil Operations
O0.0
Non-Latching Coil: O0.0 is energized if signal
reaches the coil, de-energized if the signal does not.
O0.0
Inverse Non-Latching Coil: O0.0 is energized
if signal does not reach the coil, de-energized if
the signal does.
O0.0
.Set & Hold Coil: O0.0 is energized once signal
S
reaches the coil, remains energized until Reset
Coil is activated.(Memorized ON)
O0.0
Reset Coil: O0.0 is de-energized once signal
R reaches the coil, remains de-energized until Set &
Hold Coil is activated.(Memorized OFF)
Allocation List Sample
I0.0
Normally Open Contact:Yes Logic
Closes when a signal is present at I0.0
I0.0
Normally Close Contact:Not Logic
Opens when a signal is present at I0.0
I0.0 I0.1 O0.1
› AND OPERATION
– realized by series connection of two NO contacts
S1 S2 Lamp
Truth Table
S1 S2 Lamp
0 0 0
0 1 0
1 0 0
1 1 1
Logic Operations
› OR OPERATION
– realized by parallel connection of two NO contacts
S1 Lamp
Truth Table
S2
S1 S2 Lamp
0 0 0
0 1 1
1 0 1
1 1 1
2.6 PLC Programming using STL
SENTENCE 1
Conditional part THEN
Executive part
SENTENCE 2
Conditional part THEN
Executive part
SENTENCE 1
Conditional part THEN ….
Commonly used commands in STL
Automotive industry
Mechanical industry
Packaging industry
Woodworking industry
Printing and paper industry
Drinks industry
Ceramics and bricks industries
Plastics industry
Electronics industry
Sensor Classifications
S e n s o r C la s s ific a t io n S e n s o r C la s s ific a t io n
A c c o r d in g t o
S e n s o r C la s s ific a t io n
P r in c ip le o f O p e r a t io n A c c o r d in g t o A c c o r d in g t o
W ir in g O u t p u t S ig n a l P o la r it y
C o n ta c t S e n s o rs
2 - W ir e S e n s o r s P N P S e n s o rs
E le c t r ic a l L im it S w it c h
P re s s u re S e n s o rs 3 - W ir e S e n s o r s N P N S e n s o rs
C o n t a c t le s s S e n s o r s
4 - W ir e S e n s o r s
M a g n e t ic
I n d u c t iv e
C a p a c it iv e
O p t ic a l
U lt r a s o n ic
Sensors
TYPES:
Contact Sensors – mechanical in nature, subject to
mechanical wear and with predictable failure rate. Contact
sensors include limit switches, roller switches, and pressure
sensors.
object
Inductive Proximity Sensor
BN
BK
Note:
For metallic BU
materials only
Sensing Distance of Inductive Sensors
Cu
Al
Ms
Cr Ni
Steel
0 20 40 60 80 100
Sensing Distance
Applications
Inductive
proximity
sensor
– This is accomplished by
means of a small, powerful
proximity switch with a long
switching distance.
Check for gripped product
BN
BK
BU
Sensing Distance of Capacitive Sensor
Thermoplastic
Duroplastic
Water
Ms,Al,Cu
Steel
0 20 40 60 80 100
Detection of boxes
Detection of liquid level inside a plastic
container
Optical Proximity Sensor
BN
BK
BU
Level control of powder
– On a production line
for resistors 10,000
units per minute are
produced.
– In order to achieve
exact counting of the
output of small
components, a
through-beam sensor
connected with a fibre
optic cable is aligned
so as to point towards
the resistors.
Checking of drill bit breakage
– A through-beam sensor
in a machining centre
controls a drill for
breaks. Before every
machining cycle, the
drill is moved to a test
position. If the drill
point is present, it
breaks the light beam
and an OK signal is
given to continue
operation
Filling control
– At the bottling plant
with a production rate
of 16,000 bottles per
hour a through-beam
sensor is adjusted in
such a manner that
the light beam
penetrates the bottle.
If in any bottle the
liquid attains the
predetermined level,
the light beam is
broken and the sensor
responds.
Checking of drill holes
– Sensor Function
– Description of the object to be detected
– Installation conditions
– Environmental conditions
– Application area
FLAGS
– Chronological Order
Cylinder 1.0 extends and lifts the box
Cylinder 2.0 extends and pushes the box
Cylinder 1.0 retracts, then
Cylinder 2.0 retracts
– Tabular Form
Work Step Motion of Cylinder 1.0 Motion of Cylinder 2.0
1 out -
2 - out
3 in -
4 - in
Representations
– Vector Diagram
Extension represented by 1.0
Retraction represented by 2.0
1.0
2.0
– Abbreviated Notation
Extension represented by : + 1.0 +
Retraction represented by : - 2.0 +
1.0 -
2.0 -
Representations
1 2 3 4 5=1
1.0
2.0
SIGNAL EDGES
RISING EDGE
– Every binary signal has a
positive and negative edge
TRAILING EDGE
– POSITIVE EDGE (RISING EDGE)
marks the moment at which a
1 change from 0 to 1 takes place (
or from OFF to ON.
1
Status of
Condition
0
Start of timer
Status of 1 Start of timer
Timer
0
Timer preset
Switch-OFF Delay Timer
(TOFFnn)
- allows outputs to be deactivated with a 0-signal after a delay time
has expired. When a rising edge is recognized for the condition, the
timer preset is loaded into the timer word. A trailing edge starts the
timer, which runs until the timer has expired or the timer is
reinitialized by a rising edge for the condition.
1
Status of
Condition
0
Status of 1 Start of timer
Timer
0 Timer preset
Pulse Timer (Tnn)
- allows an output to be activated for a specified time when an input
signal is present. It only reacts to the rising edge of the condition. This
pulse starts the timer (Tnn=1). The timer preset is loaded into the
timer and the timer starts to decrement until it reaches a value of zero,
or a further edge (pulse) is detected at the conditional part, restarting
the timer, or the timer is reset (Tnn=0).
Rising edge
1
Status of
Condition
0
Status of 1
Timer Timer preset
0
Start of timer on rising edge
Representations
– Counter status - Cnn
- indicates whether the counter is activated or deactivated.
It is a one-bit operand that can be set, reset, or
interrogated.
– Counter preset - CPnn
- represents the end value for incremental counters and the
start value for decremental counters. Ranges from 0 to
65535.
– Counter Word - CWnn
- is a non-permanent multibit operand and indicates the
current counter status.
Spindle Drive
INDUCTIVE
SENSOR
CARRIAGE
SHAFT
REED
SWITCH
GEAR
MOTOR
Vacuum Generator
P
R
P R U
– Workpieces with smooth and
impervious
surfaces can be picked up and held
(for
transporting and assembly) with
this
vacuum generator
– This produces vacuum in
U accordance
with the venturi principle, using the
compressed air from P to R.
Relays
24 V
OUTPUT 2
PLC OUTPUT 1
K1
K2
K1 K2
MOTOR --
BLUE MOTOR --
WIRE RED WIRE
0 V
REGISTERS
– Used to store binary, octal or decimal values
– Interrogating a register =
V20
( conditional part )
R10
R4
– Incrementing INC
( executive part )
R50
– Decrementing
DEC
( executive part )
MULTI-TASKING
MAIN
P0
P1 P2 P3 P4
AUTOMATIC MANUAL RESET EMERGENCY STOP
MULTI-TASKING
– A program can be
activated (started) and
P1
PB1 deactivated (stopped)
from within another
S program or module.
P2 – The program is
activated by setting the
R operand Pn, and
deactivated by resetting
it.
PB2 P1