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1
Student Name Arjun Pratap Singh
Discipline Mechatronic Engineering
Module Name PLC & Pneumatic System
2
Table of Contents
1 Introduction 3
2 Objective 6
3 PSIM Simulator
3.1 The Silo Simulator 7
3.2 The Batch Mix Lab Utilizing PLC Counters 13
4 Rotational Position System with DC Motor and Encoder
4.1 Connection Diagram 23
4.2 Ladder Logic Diagram 24
5 Pneumatic Palletizing and Punching System Design
5.1 3D Pneumatic Automation System Design 28
5.2 Component Selection 29
5.3 Implementation of Pneumatic Automation System
Using Pure Pneumatic Control 31
5.4 Implementation of Pneumatic Automation System
Using Electro Pneumatic Control 32
6 Discussion and conclusion 37
7 References 38
3
Introduction
Programmable logic controllers are used in industry in many areas of automation and technology
as well as for control and regulation tasks. A PLC is a device with specialized input and output
interfaces. These interfaces (sensors and actuators) regulate, controls and monitors
manufacturing processes. Because the machines are getting more and more complicated,
industries won't be able to do without PLC programs. It is even possible to program and control
PLCs via data radio communication or radio relay system. It is also possible to write PLC
programs, implement error detection and correct errors via remote maintenance.
Programmable logic controllers are used for automation, monitoring and regulation of
technical processes. Here are few examples where programmable controllers can be used:
Control of an escalator
Control of a conveyor system
Control for filling a silo
Control of a bottling plant
Control of a traffic light system
Control of parking deck
Control of an automatic welding system
PLC were invented to do away with the hardwire logic, which was usually done using
number of sequential relays to control a machines operation. Below are few of the advantages of
using PLC’s:
Simplified Changes (changes in operation and circuit can be done easily by use of
programming)
Material and Space is saved (as number of relays aren’t use for control)
Duplications of Programs (program can be copied from one place to another without
trouble)
Comments and Documentation Possible (for easier understanding of the logic used)
Saving Time (less installation time, less cabling and parallel programming)
4
Remote Maintenance and Diagnosis (easily monitored and controlled from remote
location)
Lower Energy Consumption
The PLC mainly consists of a CPU, memory areas, and appropriate circuits to receive
input/output data. It is possible to consider the PLC to be a box full of hundreds or thousands of
separate relays, counters, timers and data storage locations. They don’t exist physically but rather
they are simulated and can be considered software counters, timers, etc. These internal relays are
simulated through bit locations in registers.
(Inside PLC) (Available from http://www.plcs.net/chapters/parts3.htm)
(PLC Operation) (Available from http://www.plcs.net/chapters/howworks4.htm)
Below the researcher has explained the basic PLC instructions briefly:
The load (LD) instruction is a normally open contact. It is sometimes also called examine
if on. (XIO) (as in examine the input to see if it’s physically on). The symbol for a load
instruction is shown below.
5
(Available from http://www.plcs.net)
The Load bar instruction is a normally closed contact. It is sometimes also called Load
not or examine if closed. (XIC) (as in examine the input to see if it’s physically closed)
the symbol for a load bar instruction is shown below.
(Available from http://www.plcs.net)
The Out instruction is sometimes also called an Output Energize instruction. The output
instruction is like a relay coil. Its symbol looks as shown below.
(Available from http://www.plcs.net)
The latch instruction is often called a SET or OTL (output latch) once on will remain on
forever. The unlatch instruction is often called a RES (reset), OUT (output unlatch) or
RST (reset) once off will remain off forever. The diagram below shows how to use them
in a program.
(Available from http://www.plcs.net)
6
Above researcher has shown and explained the basic instructions in PLC, more advanced
instruction include counters, timers, one shots, master controls, shift registers, getting and
moving data and math instructions.
For the given assignment, in the first part researcher has used PSIM software to control
the silo simulator and batch mixer, in the second part researchers have used rslogix 500 software
along with OMRON PLC to control dc motor rotational position aided by encoder and for the
last past researchers have used automation studio software to design an pneumatic automatic
system.
Pneumatic systems mainly comprise of pneumatic actuators which act due to change in
pressure of air. Pneumatic cylinder and valves are there to control and regulate air which is the
acting force; various mechanical works are done by the air pressure. In this assignment
researchers have designed a pneumatic system whose actions are controlled using PLC’s ladder
logic.
Objectives
For the given assignment the researchers are put with 3 main objectives, first objective is
creating ladder logic control for silo simulator and batch mixing which has to be achieved
individually, the second objective is creating ladder logic control and use OMRON PLC to
control dc motor’s rotational position which has to be achieved in a group and the last objective
is designing a pneumatic automation system which is controlled using ladder logic, which has
also to be achieved in a group.
7
Part 1: PSIM Simulator (Individual)
The Silo Simulator
(Flow Chart for SILO Simulator) (Constructed using MS Word)
8
(The Silo Simulator at Start) (Available from PSIM Simulator)
(The Silo Simulator at Standby Mode) (Available from PSIM Simulator)
9
(The Silo Simulator at Run Mode) (Available from PSIM Simulator)
(The Silo Simulator at Full Mode) (Available from PSIM Simulator)
10
(Toggle Table, the process is repeated 3 times on 4 th time the box is filled but is not cleared by
the conveyer belt) (Available from PSIM Simulator)
(Ladder Logic 1 for the SILO Simulator) (Available from PSIM Simulator)
1
4
3
2
5
11
(Ladder Logic 2 for the SILO Simulator) (Available from PSIM Simulator)
RUNG INSTRUCTION
1 When switch F2 is switched on or level sensor has detected high level and full light is on and count
has not reached 4 latch the motor to run
2 When switch F1 is pressed or photo switch detects box and full light isn’t on unlatch the motor to
stop
3 When motor is running on the run light
4 When photo switch detects box latch the solenoid valve to open
5 When full light is on and motor is running or when count is over unlatch the solenoid valve to close
6 When run light is on unlatch the solenoid valve
7 When level sensor detects high level on the full light
8 When photo switch doesn’t’ detect anything unlatch or off full light
9 When photo switch detects box on standby light
6
9
8
10
7
11
12
10 Whenever full light is switched on increases the counter by 1
11 When switch F3 is pressed reset the counter, thus resetting the process
Above, researcher has shown the screen shots of the silo simulator in action, below which he has
shown the ladder logic developed by him to control the silo simulator along with the flow chart
for easier and better understanding and below which he has explained each rung of the ladder
logic. The process of silo simulator has be designed as asked by the assignment which is, system
should be started once the start switch (F2) is pressed, which means the conveyer should run and
run light should be on, the system should stop or pause when stop switch (F1) is pressed, all the
processes are to be halted and standby light should be on. The box should stop when right edge
of the box is sensed by the photo sensor or switch (stop the conveyer when sensed), after which
the standby light should come on and solenoid valve should open and pour the liquid into the
box. While this process is going on, when level sensor detects the high level, the full light should
come on and the solenoid valve should close and the conveyer should restart again. This process
has to be repeated 3 times, but the researcher designed the system in such a way that the box will
be filled 4 times but the box will be cleared of the system only 3 times. For deeper technical
understanding, the researcher urges reader to go through the rungs operation above in the ladder
logic.
13
The Batch Mix Lab Utilizing PLC Counter
(Flow Chart for Batch Mixer) (Constructed using MS Word)
14
(The Batch Mix Lab at Start) (Available from PSIM Simulator)
(At Run Mode, P1 working) (Available from PSIM Simulator)
15
(At Run Mode, P2 working and P1 stop) (Available from PSIM Simulator)
(At Full Mode, Hi – Level ON, Mixer ON and Heater ON) (Available from PSIM Simulator)
16
(At Standby Mode) (Available from PSIM Simulator)
(Heater OFF desired temperature reached, Mixer on 4 sec) (Available from PSIM Simulator)
17
(At Run Mode, P2 Stop, P1 Stop and P3 Working) (Available from PSIM Simulator)
(At Run Mode P3 Stop, Low Level OFF and P1 Working) (Available from PSIM Simulator)
18
(Ladder Logic 1 for the Batch Mix Lab) (Available from PSIM Simulator)
(Ladder Logic 2 for the Batch Mix Lab) (Available from PSIM Simulator)
1
2
5
4
3
9
8
7
6
19
(Ladder Logic 3 for the Batch Mix Lab) (Available from PSIM Simulator)
(Ladder Logic 4 for the Batch Mix Lab) (Available from PSIM Simulator)
10
11
15
14
12
13
16
19
18
17
20
(Ladder Logic 5 for the Batch Mix Lab) (Available from PSIM Simulator)
(Ladder Logic 6 for the Batch Mix Lab) (Available from PSIM Simulator)
RUNG INSTRUCTIONS
1 When switch F2 is pressed the system starts and run light is on
2 When switch F1 is pressed the system stops or pauses and run light is off
3 When flow valve 2 is activated pump P2 can pump 30 liters of liquid into vessel
4 When flow valve 1 is activated and low level sensor is on pump P1 can pump 30 liters of liquid into vessel
5 When run light is on, P2 is off and value through flow valve 1 is less than 29 liters latch on P1
6 When value through flow valve 1 is greater than or equal to 28 or run light is off stop or unlatch P1
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233
22
20
24
25
26
21
7 When run light is on, P1 is off, quantity through flow valve FL2 is less than 29 and quantity through flow valve P1 is 28, latch or start pump P2
8 When value through flow valve 2 is greater than or equal to 28 or run light is off stop or unlatch P2
9 When values through flow valve 1 and 2 are equal to 28 switch on or latch the full light
10 When run light is on, high level sensor is on, full light is on, temperature is less than or equal to 30 degrees and pump P3 is closed switch on or latch the heater
11 When run light is on, high level sensor is on, full light is on, temperature is less than or equal to 30 degrees and pump P3 is closed switch on or latch the mixer
12 When temperature equals 30 degrees , make the fictitious output on or latch it
13 When low level sensor is off, make the fictitious output off or unlatch it
14 When the fictitious output is on or run light off unlatch or off the heater
15 When the heater is off, fictitious output is on and mixer is on, start the retentive timer till it reaches 4 seconds mark
16 Once the timer has reached 4 seconds and P3 is off or run light is off unlatch or switch off the mixer
17 When the run light is on, heater is off, pumps 1 & 2 are off and mixer is off, on or latch the pump P3
18 When low level sensor is off or run light is off unlatch or off the pump P3
19 When low level sensor is off reset the flow meter valve FL1
20 When low level sensor is off reset the flow meter valve FL2
21 When low level is off, pump P3 is off, P1 is off then reset timer T1
22 When high level sensor is off unlatch or off the full light
23 When mixer is on start the retentive timer T2 to calculate the operation time for mixer
24 When heater is on start the retentive timer T3 to calculate the operation time for heater
25 When the run light is off standby light is on
26 When flow meter valve FL3 is on the counter C3 is switched on by which it means it counts the value of output through the pump P3.
Above, researcher has shown the screen shots of the batch mixer lab utilizing PLC counter in
action, below which he has shown the ladder logic developed by him to control the batch mixer
lab along with the flow chart for easier understanding and below which he has explained each
22
rung of the ladder logic. The process of batch mixer lab has be designed as asked by the
assignment which is, the system should start as soon as switch S2 is pressed, once that happens
the run light should come on and pump P1 should start pumping the liquid into the vessel while
pump P2 is still off. The amount of quantity through P1 is controlled by the researcher, which is
exactly half the volume of the vessel, once the vessel is filled half, the P1 stops and P2 takes over
pumping the liquid into the vessel. As, soon as the high level sensor over the vessel detects that
vessel is full, the full light comes on and the P1 and P2 stop functioning, while at same time the
heater is switched on to get the temperature of the liquid in the vessel to the set point. As soon as
the temperature sensor detects the temperature has reached the desired value, the heater switches
off. All this while since the full light came on the mixer has been turning, even when heater was
on. Now once the desired temperature is reached, the heater switches of immediately but the
mixer runs for extra 4 seconds before switching off. Once those 4 seconds are over pump P3
opens up and starts to drain the liquid in the vessel to some other place, once the volume of the
liquid is virtually none in the vessel, the low level sensor detects (switching off) it, and causes
the P3 to be closed and P1 to start pumping the liquid into the vessel again. This process is
continuous, it won’t stop until someone presses the switch S1, which cause the system to halt or
stop completely by switching off the run light and switching on the standby light. For deeper
technical understanding readers are urged to go through the rungs operation above in the ladder
logic.
(This parts ladder logic was done by the researcher after discussing with some classmates
and researching a lot on internet as system wasn’t working perfectly after number of tries)
Part 2: Rotational position system with DC motor and Encoder (Group)
23
The figure below shows rotational position system with DC motor and Encoder. OMRON PLC
programmed using rslogix 500 is used to control DC motor and Encoder. The programming
sequence desired is as following:
1. The DC motor must have 3 different positions by using 3 different switches.
2. The encoder is used to detect the positions.
3. The DC motor must be able to rotate CCW and CW 2 switches.
4. The system must also have a single start and stop switch.
(Rotational position system with DC motor and Encoder) (Available from the Lecturer)
Connection Diagram
(Connection diagram of Rotational Position System) (Available from Soh Boon Heng)
24
10A enhanced DC motor driver MD10B is connected between DC motor and PLC, to protect
PLC from back EMF generated from the motor and also to control the motors speed and
direction parameters.
Seven (7) inputs pins or ports have been used on the PLC’s input card, they are as following:
I: 000 (Output of infrared channel fiber optics sensor – working as an encoder)
I: 001 (Switch to control the direction of rotation – CW/ON or CCW/OFF)
I: 002 (Switch to stop dc motor at position 1 defined by the researchers)
I: 003 (Switch to stop dc motor at position 2 defined by the researchers)
I: 004 (Switch to stop dc motor at position 3 defined by the researchers)
I: 005 (Switch to reset the counter)
I: 006 (Switch to Start/Stop the dc motor)
Three (3) output pins or ports have been used on the PLC’s output card, they are as following:
O: 105 (Connected to PWM pin of MD10B to control the dc motors speed)
O: 106 (Connected to DIR pin of MD10B to control the direction of dc motor)
O: 107 (Connected to RUN pin of MD10B to control the direction of dc motor)
Programming (Ladder Logic)
(Rung 1) (Constructed on rslogix 500)
25
In rung 1, 3 switches are connected to reversible counter or bi – directional counter
(up/down). When I: 001 is ON the dc motor moves in forward direction, while I: 000 aides in
increasing the counter while in forward direction (the fiber optic sensors output goes high when
white color is detected and low when black is detected. Researchers painted a black plus sign on
circular white sheet, which was attached to the rotating shaft of the dc motor). This function
reverses when I: 001 is OFF. The final switch in this rung is I: 005 which is there to reset the
counter, but hasn’t been used or shown in demonstration as, the starting position of the dc motor
has already been identified and recorded by the counter, if counter is to be reset, the a new
starting position would be set, as where the dc shaft is positioned currently.
(Rung 2, 3, 4) (Constructed on rslogix 500)
26
Rungs 2, 3 and 4 work in similar manner. That is 3 positioning switches are connected in
series, any one of them is supposed to be ON while other 2 OFF. For example, in rung 2, switch
number I: 002 is ON while others are OFF. Thus, the comparator to which switches are attached
will compute if the number of counts by the counter is equal to the condition specified by rung 2,
for this case the value is 3. So, when count value in the counter gets to 3, then according to rung
2, the motor (Q: 104) will stop at the position where, P_EQ value becomes equal to counter
value specified by the rung and Q: 101 (function) will go true or be ON. For rungs 3 and 4 the
values are 6 counts and 9 counts.
(Rung 5 to 10) (Constructed on rslogix 500)
27
Rung 5 is controlling the start and stop of the dc motor. As, can be seen switch I: 006 is
attached to this rung, thus when the switched is pressed the dc motor stops in its tracks and
doesn’t move or when the dc motor reaches its position as defined by the positioning switches, it
stops completely.
Rung 6, 7 and 8 are to generate PWM signals. In rung 6, after DC motor is activated,
timer T0023 is started and will run for 10ms. This period is also known as on period of PWM
signal. In rung 7, when timer T0023 reaches 10ms, second timer T0024 is activated for 300ms.
Back in rung 6, when timer T0024 is activated, timer T0023 is deactivated. This 300ms period is
known as off period of PWM signal. In these rungs the PWM is being created by switching on
the dc motor for some time then switching it off for some time. Rung 8 is just controlling the
output to the MD10B, at one time O: 105 it high and at other its low, thus creating ON/OFF or
High/Low effect required for PWM. Speed of dc motor can be varied by changing the time
intervals.
Rungs 9 and 10 are used to control the directions of the dc motor, when switch I: 001 is
pressed in one direction dc motor rotates in one direction as DIR pin goes high and the RUN pin
goes low, and when switch I: 001 is pressed in other direction dc motor rotates in other direction
as now DIR pin goes low and RUN pin goes high. This characteristic or functioning of MD10B
can be seen in its datasheet or manual.
(Practical of Rotational Position System with DC motor and Encoder)
28
Part 3: Pneumatic Automation System Design (Group)
3D Pneumatic Automation System Design (Working)
(3D design of Pneumatic Palletizing and Punching System) (Constructed using Autodesk
Inventor, 2010)
The above pneumatic automation system is used for palletizing and punching metal plates. This
can be used in manufacturing industry where punching metal plates for holes and placing them in
stack manually is tiresome and slow. Thus, in the design researchers use 4 electro pneumatic
cylinders (can be controlled by PLC). For starting or initial configuration, the cylinders are
positioned such that the whole system is to top upper left corner (X Axis not extended, Y Axis
not extended, Z Axis not extended and 4th Cylinder not extended). The metal sheet is put onto the
base of the system, which may be done manually or using some other automated means. Once
it’s put there, the 3rd cylinder (Z Axis) extends down; this cylinder has punching tool attached to
it, after punching the 3rd cylinder retracts back to original position, after which 1st cylinder (X
29
Axis) extends, and 3rd cylinder (Z Axis) extends, punches hole and retracts, after which the 2nd
cylinder (Y Axis) extends and the 3rd cylinder punches holes, after which the 2nd cylinder (X
Axis) retracts and 3rd cylinder punches holes, At last the 2nd Cylinder retracts to get the
configuration of the system to initial.
After the process is over, 4 holes have been punched through the metal sheets at 4
different corners of rectangular sheet of metal. For, be able to put a new sheet on the base, the 4 th
cylinder extends and pushes out the punched metal sheets from the base after which it retracts
back to original position.
Components Selection
The components for this pneumatic automation system were selected from FESTO as they are
the leading suppliers of electrical automation and pneumatic technology. Researchers could
easily find components to choose from, for the pneumatic automation system design from their
website. The part file and assembly file for Autodesk inventor (3D design) has been imported
from the website itself. All components specification, like piston diameter, rod length, and stroke
length, follows standards set by FESTO.
Actuators chosen for the system are the double-acting cylinders which are directly
controlled by 4-way directional valves. Double – acting cylinders extend or retract by changing
the pressure of the compressed air. To control these cylinders researchers use 4-way directional
valves, they have two inputs (pressurized air) and two outputs (exhaust). For extension of the
actuator (cylinder) pressurized air is given to one of the inputs of the valve, and to retract
vacuum is created by letting pressurized air out (exhaust) through one of the outputs of the valve.
Below researcher have shown the specification of the pneumatic actuator (Cylinder)
chosen for the pneumatic automation system from FESTO:
30
(Specifications for Standard cylinder DSNU-25-200-PPS –559257) (Available from
http://www.festo.com)
31
Implementation of Pneumatic Automation System using Pure Pneumatic Control
(Part 1 for Fully Pneumatic Control) (Constructed using Automation Studio)
(Part 2 for Fully Pneumatic Control) (Constructed using Automation Studio)
(Part 3 for Fully Pneumatic Control) (Constructed using Automation Studio)
32
The components used above system are the double acting pneumatic cylinder, 3/2 normally
closed valve with roller and spring returns (acts as touch sensor), 5/2 valve (14) is used to control
pressure in or out of double acting cylinder. Sequential logic step modules are used to allow the
cylinder to be extended or retracted, following a certain sequence. Start switch and stop switch is
applied to control the operation of system.
From the figure above (Part 3 for fully pneumatic control), at first, once the start switch is
pressed, the process starts, the sequential logic starts from 1. Cylinder C is extended until roller
C1 is touches by the shaft of cylinder C. When it reaches C1, sequential logic jumps to 2. The
similar process is repeated until sequential logic reaches 8. These sequences will move the object
to 4 different positions for punching (4 corners), and remove the metal sheet after the processes
finish. If the slider start switch is not toggle off, the whole process will be repeated again, if it is
turned off, the process stops at sequential logic 8. Emergency switch can be used to stop the
whole process at any point of time (cuts of the supply).
Implementation of Pneumatic Automation System using Electro Pneumatic Control
(Pistons used for the Electro Pneumatic Control) (Constructed using Automation Studio)
33
(PLC Ladder Logic for 1st, 2nd and 3rd table) (Constructed using Automation Studio)
1
2
3
4
5
6
7
8
9
10
11
12
15
14
13
20
19
18
17
16
23
22
21
34
(PLC Ladder Logic using 4th, 5th and 6th table) (Constructed using Automation Studio)
27
26
29
31
24
30
25 33
34
28
32
37
36
35
39
38
49
48
47
46
45
50
43
44
42
41
40
35
From the figures above, 1st table is for drilling process, punching holes at initial position and then
retracting it drill actuator back, 2nd table if for the drilling process at position 2, 3rd table is for
drilling process at position 3 and the 4th table is for drilling process at position 4. The positions
defined are the 4 corners of the metal sheet. The drilling process or the ladder logic at the initial
position has been explained in brief, other tables are very similar to the 1st table, except that there
are new positions to move to along X, Y and Z axis. 5th table is to get back to the initial position
and the last table or the 6th table is to push the metal sheet out of the system’s base.
RUN
G
INSTRUCTIONS
1 DRILL latch (S1) to start drilling, piston moves downwards
2 deactivated when BACK is activated, bring piston upwards and stop drilling
3 activate latch back when D2 and DRILL are ON ,D2 is the maximum position of actuator one
4 activates the input S2 when back is ON and drill done is OFF, indicates 1st process is over
6 activate the DRILL DONE latch when the drill arm has retracted back to its initial position D1
and that the back latch is ON
7 unlatch the DRILL latch and the BACK latch when the DRILL DONE latch is activated
8 the STEP1 latch is activated when the DRILLDONE is ON and the STEP2 and LATCHTO3 is
OFF (new position)
9 activate the S3 switch when STEP1 is ON and STEP2 is OFF, activating S3 will extend the
second actuator until STEP2 is ON
10 STEP2 is activated when STEP1 is still ON and D4 is activated which means the second
actuator has reached the maximum position D4. Thus STEP2 is activated which will disable the
8th and 9th rung
11 unlatch the DRILLDONE latch whenever the STEP2 latch is activated meaning that the
program must run the drill program again but this time in the second location of the metal piece
12 DRILL is latched when STEP2 is ON, BACK and DRILLDONE is OFF. This means that the
drill process is started from STEP2 but this rung must be disabled when the BACK and
DRILLDONE is ON so that the DRILLDONE from the 6th rung can unlatch the DRILL
13 activate the LATCHTO3 latch when the STEP2 latch is activated, the LATCHTO3 latch
indicates that the second piston has reached its designated position
14 STEP1 and STEP2 are unlatched when DRILL is ON to allow other latches such as STEP3 and
STEP4 to latch the DRILL in the next program without any conflicts15
36
36 The 36th rung is responsible for activating the push piston
To start this whole process HIT IT switch needs to be pressed, once it’s pressed the
electro pneumatic automation system comes to life, the drilling process is done at initial position
(finish process – DRILL DONE), and then the process is repeated at 2nd, 3rd and 4th position.
After finishing drilling process at these positions the system comes back to original or initial
position and at last the metal sheet is pushed (PUSH) out of the base to make room for new one.
The process ends when one complete cycle is over. Below researcher has explained what does
the main terms used in the ladder logic means:
DRILL Go down and drill a hole
BACK Go up after drilling hole
DRILL DONE Drilling process at a particular position is completed
HIT IT Start the system
D(X) Various positions (4 corners)
STEP(X) Indicates piston (X) reached its desired position
LATCHT(0X) Piston reached its pos., program must be prepared for next process
PUSH Removes the metal sheet or piece
WITHDRAW Similar to BACK
FINISH Similar to DRILL DONE
(X) Positive Integer
Discussion and Conclusion
Researcher has achieved all the objectives defined above as, he constructed ladder logic using
PSIM simulator software to control SILO SIMULATOR which is or can be used for filling
bottles at bottling plant and to control BATCH MIXER which is used mix 2 or more substances
or cool down the temperature at large industries such as refineries (individual), after which
research and his group mates were able to control the rotational position of dc motor with the
help of OMRON PLC, MD10B motor driver, RSLOGIX 500 software to construct the ladder
logic for the control, and optic fiber sensor which acted as the encoder and at last researcher and
group mates were able to develop a pneumatic automation system which can be used for
palletizing and punching holes through metal sheets at positions defined, the design developed
37
was test for fully pneumatic and electro pneumatic control separately. The controlling of the
electro pneumatic system was done using ladder logic (PLC) in AUTOMATION STUDIO
software, and the designing part was done in Autodesk Inventor 2010.
As, such researcher and his group mates did not face much trouble doing the assignment,
but there were some issues related to use of quadrature encoder as the outputs of the encoder
could not be properly read, unless programmed with a microcontroller and the other issue which
researchers came across was related to the automation studio software, same sequences weren’t
working at different steps, by which it means, if a sequence has been done at a particular step it
won’t be repeated at another step, as the researchers desired.
After doing this assignment researcher has gained massive knowledge which would be
really handy when he starts working. As, this assignment was focused on industrial automation,
the researcher learnt how to control things using PLC, which is popular in various industries for
control and monitoring operations.
38
References
Cytron Technologies Sdn Bhd, 2008, [ONLINE] Available at:
http://www.cytron.com.my Accessed on 5 Sep 2011
Festo 2011 [ONLINE] Available at: http://www.festo.com [Accessed, 30th September
2011]
MikroElektronika: books: Introduction to PLC controllers. [ONLINE] Available at:
http://www.mikroe.com/old/books/plcbook/plcbook.htm [Accessed, 30th September
2011]
PLC Programming, EN 61131, IEC 61131. [ONLINE] Available at:
http://www.automation-course.com/plc-programming/ [Accessed, 30th September
October 2011]