Exp # 8

Programming the Complete System

Objective:

Produce a start-up sequence program.

Produce a program that sorts components by height.
Produce a program that sorts components by width.
Produce a complete processing system program.

Equipment:
Personal Computer with RSLogix programming software and RSLinx
communication software (installed).
PC45 Programmable Controller Trainer with Allen-Bradley MicroLogix 1500 PLC.
PC-MicroLogix 1500 Serial programming cable.
PC45 Accessory Kit.
PC49 Hand Held Compressor Pump.
Flat Blade Screwdriver.

Introduction
In this chapter you will be presented with a number of programming exercises. Each of these
exercises uses the programming skills and knowledge that you have gained from working
through chapters 1 to 9. Tables 10.1 to 10.3 show the connections that should be made between
the PC45 Trainer, MicroLogix 1500 PLC and Sequence Switch Module in order to complete the
programming exercises of this chapter.

When the cylinders of the PC45 Trainer are used, you will need to have the hand compressor
lump connected.
To connect the hand compressor pump, attach the end of the hand compressors hose by
pushing it firmly into the connector on the PC45 Trainer (shown in Fig 10.1 below).

Twist the handle of the hand compressor pump by 90 to release it from its housing, then pump
the handle up and down until a force is felt restricting more air from being entered into the
canister. Press the handle down into its housing, then twist the handle by 90 to secure it in
place.
Note: As the cylinders on the PC45 Trainer are operated, air pressure drops in the hand
compressor, so additional air will need to be pumped in as the system is used.

Programming Exercise 10.1

In this programming exercise you will develop a start-up sequence program for the PC45 Trainer
that performs the following:
(i)
The green push button can only start the system when switches S1, S2 and S3 on the
Sequence Switch Module are closed, then opened in turn (S1, then S2, then S3).
(ii)
When switches S1, S2 and S3 have been closed then opened, the operator will only
have 5 seconds in which to press the green push button, otherwise the system will
shut down and the conveyor will not be able to be started.
(iii)
While the system is shut down the red lamp should be lit. During the 5 second period
that the operator has to start the system, both the red and green lamps should be off.
(iv)
If the system shuts down before the green push button is pressed, switches S1, S2 and
S3 would then have to be operated in sequence again before the green push button
could be used to start the system.
(v)
If the green push button is pressed in the 5 second time period, it will turn on the
conveyor in the reverse, left to right, direction and the green lamp will light.

(vi)

If the red push button is pressed either during the 5 second time period or while the
system is operating, the system will be shut down and switches S1, S2 and S3 will
need to be operated in sequence again before the system can be re-started.

Programming Exercise 10.2

In this programming exercise you will develop a program that sorts the components in the PC45
Accessory Kit by height. The program should perform the following:
(i)
The green push button should be used to start the conveyor in the forward, right to
left, direction.
(ii)
While the conveyor is operating, the green lamp should be lit. When the conveyor is
stationary, the red lamp should be lit.
(iii)
Use Sensor 1 on the conveyor to determine if a component is tall or short. (Should be
set to detect a tall component.)
(iv)
Sensor 2 on the conveyor is used to start timing for either a tall or short component.
(Should be set to detect all components.)
(v)
Cylinder 2 (the center cylinder) is operated when a tall component reaches it.
(Remember that Microswitch 2 is activated when Cylinder 2 is operated.)
(vi)
Short components should move the full length of the conveyor, being rejected by
falling off the far end.
(vii) If the red push button is pressed, the conveyor should stop, any timing taking place
should be stopped and the content of the accumulator held at its last value.
(viii) Pressing the green push button should re-start the conveyor and timing if previously
stopped.
Note: The components should be placed on the right-hand end of the conveyor.
Hint: This program is similar to Programming related to RTO, TON,which is done previously.
You can use Programming Exercise as a guide to developing this program.

Programming Exercise 10.3

In this programming exercise you will develop a program that sorts the components in the PC45
Accessory Kit by width. The program should perform the following:
(i)
The green push button should be used to start the conveyor in the forward, right to
left, direction.
(ii)
While the conveyor is operating, the green lamp should be lit. When the conveyor is
stationary, the red lamp should be lit.
(iii)
Use Sensor 1 on the conveyor to determine the width of a component. (Sensor 1
should both be set to detect all component heights.)
(iv)
Sensor 2 on the conveyor is used to start timing for all components.
(v)
Cylinder 1 (cylinder furthest from the sensors) is operated when the narrowest
component reaches it.
(vi)
Cylinder 2 (the center cylinder) is operated when middle sized component reaches it.
(vii) Cylinder 3 (cylinder closest to the sensors) is operated when the widest component
reaches it.

(viii)
(ix)
(x)

If the red push button is pressed, the conveyor should stop, any timing taking place
should be stopped and the content of the accumulator held at its last value.
Pressing the green push button should re-start the conveyor and timing if previously
stopped.
When six components have been sorted into their appropriate compartments, the
conveyor should be stopped.

Programming Exercise 10.4

In this programming exercise you will combine programming exercises 10.1, 10.2 and 10.3 into
a single program that provides the full range of sorting operations on the PC45 Trainer. Again
the components in the PC45 Accessory Kit shall be used.
The program should perform the following:
(i)
The system should be started using the start-up sequence developed in Programming
Exercise 10.1. The conveyor should be operated in the forward, right to left, direction.
(ii)
Use Sensor 1 on the conveyor to determine if a component is tall or short. (Should be
set to detect a tall component.)
(iii)
Use Sensor 1 on the conveyor to determine the width of a component.
(iv)
Use Sensor 2 on the conveyor to start timing for the appropriate width and/or height
of component. (Should be set to detect all components.)
(v)
Short components should move the full length of the conveyor, being rejected by
falling off the far end.
(vi)
Cylinder 1 (cylinder furthest from the sensors) is operated when the tall narrowest
component reaches it.
(vii) Cylinder 2 (the center cylinder) is operated when middle sized tall component reaches
it.
(viii) Cylinder 3 (cylinder closest to the sensors) is operated when the widest tall
component reaches it.
(ix)
If the red push button is pressed, the system should be shut down, any timing taking
place should be stopped and the content of the accumulator held at its last value.
(x)
When all six components from the PC45 Accessory Kit have been sorted, the system
should be shut down. However, the system should not shut down before either the last
component has been pushed off by a cylinder, or it has run off the end of the
conveyor (depending on the height).
(xi)
If the system has been shut down, or all six components have been sorted,
switches S1, S2 and S3 will need to be operated in sequence again before the system
can be re- started.
Note: The components should be placed on the right-hand end of the conveyor.

Notes:
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