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EE018-3.

5-3

Group Assignment

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PLC and Pneumatics Assignment

Learning Outcome 1) Program PLCs to control robotic systems. 2) Analyse and apply PLC control. 3) Provide detailed solutions to real control problems. 4) Compare and appraise continuous control (open, closed loop) with a PLC approach. 5) Critically evaluate the role of robots using PLC in the current state of the art methods.

This assignment introduces the students to PLC programming and pneumatic circuit design. Students should be able to use PSIM simulator and demonstrate the PLC programming functions. Students should be able design pneumatic circuit and simulate the output with the Automation studio software.

UCTI Level 4

Asia Pacific University College of Technology and Innovation

201102

EE018-3.5-3

Group Assignment

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Tasks to be done This assignment consists of two parts which are individual component and group component are stated below: Part 1(Individual Component) i) PLC programming using ladder logic for the Silo simulation. ii) PLC programming using ladder logic for the Batch mixing process. Part 2 (Group component) i) PLC motor control ii) Motors must be interface using drivers to the PLC Part 3 (Group Component) i) Pneumatic circuit design. ii) PLC programming using ladder logic for the control of the suggested pneumatic circuit design. Part 1(Individual Component) The Silo Simulator Figure 1 shows the silo simulator with all its components.

Figure 1: Silo simulation system


UCTI Level 4 Asia Pacific University College of Technology and Innovation 201102

EE018-3.5-3

Group Assignment

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Design and test a ladder control circuit for the Silo Simulator which will incorporate the following Sequence of Operations: i) Start the conveyor when the Start Switch ([F2] key) is momentarily pressed. ii) Stop the conveyor when the Stop Switch ([F1] key) is momentarily pressed. iii) Energize the RUN status light when conveyor is moving. iv) Stop the conveyor and energize the STANDBY light when the right edge of the box is first sensed by the photo-sensor. v) With the box in position and the conveyor stopped, open the solenoid valve and allow the box to fill. Filling should stop when the Level sensor goes true. vi) Energize the FULL light when the box is full. The Full light should remain energized until the box is moved clear of the photo-sensor. vii) The process should repeat for 3 cycles. The Batch Mix Lab Utilizing PLC Counters Figure 2 shows the batch mixing system and all its components.

Figure 2: Batch mixing system


UCTI Level 4 Asia Pacific University College of Technology and Innovation 201102

EE018-3.5-3

Group Assignment

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The Advanced Batch Mixing Lab A Programmable Batch Mixing System Using your knowledge of PLC instructions, design a program to meet the following requirements: i) The batch mixing process will run as a continuous operation which may be stopped or started at any time using switches S1 and S2. ii) The tank is to be filled with a mixture obtained from the separate fill lines using pumps P1 and P2. A counter will control the quantity of product obtained from Line 1 (P1) while the remainder will come from Line 2 (P2). The tank is filled to the point where the Hi-Level sensor turns ON. iii) When filling is completed, the Full light will turn ON. Heater O:1/04 and Mixer O:1/00 will be started allowing the mixture to begin heating. Thermostat I:1/04 is used to control the temperature limit. iv) The mixer will continue to run for 4 seconds after the mixture reaches the desired temperature. When the mixer stops, pump P3 will be used to drain the product from the tank. The tank will be drained to the point where the Lo-Level sensor turns OFF. v) Once emptied, the fill, mix, heat process will repeat. vi) A second counter will be used to track the number of batches that have been mixed. The batch count will be controllable by adjusting the counter's preset. vii) Separate counters will be used to track the quantity of product that has been taken from the 2 individual fill lines. viii) Run-time timers will be used to keep track of the accumulated Mixer, and Heater operation times.

UCTI Level 4

Asia Pacific University College of Technology and Innovation

201102

EE018-3.5-3

Group Assignment

Page 5 of 9

Part 2 (Group Component) In this part OMRON PLC will be used to control real life automation application. The devices that can be control are motor and sensors. Students can select 1 of the 4 given task below. 1) DC motor speed and direction control For this task a 12V DC motor with a motor driver must be connected to the PLC as shown in Figure 3 below.

DC motor

DC motor driver

PLC

Figure 3 The programming sequence The DC motor must have 3 different speed controls by using 3 different switches. The DC motor must be able to rotate counter clockwise (CCW) and clockwise (CW) using 2 switches. The system must also have a single start and stop switch. 2) DC motor speed control with acceleration and deceleration For this task a DC motor is used with the DC motor driver which is connected to the PLC as shown in the Figure 4 below.

DC motor

DC motor driver Figure 4

PLC

UCTI Level 4

Asia Pacific University College of Technology and Innovation

201102

EE018-3.5-3

Group Assignment

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The programming sequence The DC motor must have 3 different speed controls which are the acceleration speed, the constant speed and the deceleration speed. The sample speed curve for the DC motor is shown in Figure 5 below. Speed Constant speed

Acceleration

Deceleration

Time The DC motor must be able to rotate counter clockwise (CCW) and clockwise (CW) using single switch. The system must also have a single start and stop switch. 3) Rotational position system with DC motor and encoder For this task a 12V DC motor and encoder with a motor driver must be connected to the PLC. The programming sequence The DC motor must have 3 different positions by using 3 different switches. The encoder is used to detect the positions. The DC motor must be able to rotate counter clockwise (CCW) and clockwise (CW) using 2 switches. The system must also have a single start and stop switch.

4) Conveyor system to sort different height of parts For this task a 12V DC motor and a motor driver and sensor must be connected to the PLC as shown in Figure 7 below. Rejection mechanism Parts High sensor Low sensor DC Motor

Figure 7
UCTI Level 4 Asia Pacific University College of Technology and Innovation 201102

EE018-3.5-3

Group Assignment

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The programming sequence The DC motor must have 2 different speeds by using 2 different switches. The sensor is used to detect the high and low parts. The system must stop when 3 low parts are detected and the part must stop at the end of the conveyer. The system must also have a single start and stop switch. 5) Stepper motor control For this task a 12V stepper motor with a motor driver must be connected to the PLC. The programming sequence The stepper motor must have 3 different positions by using 3 different switches. The stepper motor must be able to rotate counter clockwise (CCW) and clockwise (CW) using 2 switches. The system must also have a single start and stop switch.

Part 3 (Group Component) Pneumatic automation system design Design a pneumatic automation system using four pneumatic actuators, sensors and limit switches. Task requirements 1) Develop the 3D design of the automation design. 2) Show how the pneumatic actuators and valves selection are used in the automation design. The selection must be done by sourcing industrial components. 3) Design the automation system using only pneumatic component without any electropneumatic control and explain the working principle of the system. 4) Design the automation system using electro-pneumatic control and explain the working principle of the system. 5) Show also the programming ladder logic method for the automation system.

UCTI Level 4

Asia Pacific University College of Technology and Innovation

201102

EE018-3.5-3

Group Assignment

Page 8 of 9

Marks distribution i) Individual Component i) PLC programming using ladder logic for the Silo simulation. (10%) ii) PLC programming using ladder logic for the Batch mixing process. (10%) iii) Presentation Students have to present the work done which explains the programs and the results. (10%) iv) Report A report also has to be submitted at the end of the assignment. Report Format o Introduction Discuss the background and similar existing system o Objective o PLC programming Flow chart given and explanations given for each of the method below: Silo simulator Batch Mixing o PLC motor control application Connection diagram given Programming is explained o Pneumatic Automation system design 3D Pneumatic Automation system design given Selection of component explained Pneumatic circuit design given and explained Electro-pneumatic design and explained o Discussion and Conclusion (15%) ii) Group Component i) Students able to show the results (10%) ii) Students able to explain the connection to the PLC (5%) iii) Students able to explain the programming logic used (5%)

UCTI Level 4

Asia Pacific University College of Technology and Innovation

201102

EE018-3.5-3

Group Assignment

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iii) Group Component i) Pneumatic Automation system design. The design in presented in 3D diagrams. (5%) ii) Pneumatic circuit design should be shown in report and explain the circuit working. Show the circuit working with the automation studio software. (10%) iii) Electro - Pneumatic circuit design should be shown in report and explain the circuit working. Show the circuit working with the automation studio software. (10%) iv) Component selection and usage should be shown in the report and selection must be justified. (5%) v) PLC programming using ladder logic for the control of the suggested pneumatic circuit design must be explained in the report. Program working should be shown with the automation studio software. (5%)

UCTI Level 4

Asia Pacific University College of Technology and Innovation

201102