Zunaib Ali - 09 Mugadsa Iftikhar - 03 Lab Report No: 11 Programmable Logic Control (PLC) Apparatu: > Internet Activated PC Theory: Every system or machine has a controller. Depending on the type of technology used, controllers can be divided into pneumatic, hydraulic, electrical and electronic controllers, Frequently, a combination of different technologies is used. Furthermore, differentiation is made between hard-wired programmable (e.g. wiring of electro-mechanical or electronic components) and programmable logic controllers. The first is used primarily in cases, where any reprogran ing by the user is out of the question and the job size warrants the development of a special controller. Typical applications for such controllers can be found in automatic washing machines, video cameras, and cars. However, if the job size does not warrant the development of a special controller or if the user is to have the facility of making ofa simple or independent program changes, or of setting timers and counters, then the us universal controller, where the program is written to an electronic memory, is the preferred option, The PLC represents such a universal controller. It can be used for different applications and, via the program installed in its memory, provides the user with a simple means of changing extending and optimizing control processes. The original task of a PLC involved the interconnection of input signals according to a specified program and, if "tue", to switch the comesponding output, Boolean algebra forms the mathematical basis for this operation, which recognizes precisely two defined statuses of one variable: "O"and "1. PLC has evolved as an important controller in industries these days because of its simplicity and robustness. It is used for controlling many mechanical movements of the heavy machines or to control the voltage and frequeney of the power supplies. The applic: include the * Continuous bottle filling system, © Batch-mixing system, = Speed control of de motor, ions, © 3 stage air conditioning system, © Control of planar machine and © The automatic frequency control of the supply, during induction heating.Zunaib Ali - 09 Mugadsa Iftikhar - 03 LAB TASK: Draw the flow chart of any industrial application and implement it using Ladder Logic. Applicatio: Continuous Bottle Filling System Thi our bottles, which are moving on the conveyor belt, to be automatically detected at the one of the important application of PLC in the bottle filling industry where we want appropriate position and get it filled by any desired liquid and also after getting filled the queued bottle gets chance to be filled. If this whole process is carried out manually it will really take a long time and also the quantities will be quite lesser. So PLC becomes requisite controller for these types of industry. Objective- We will implement a control program that detects the position of a bottle via a limit switch then waits for 0.5 secs, and then fills the bottle until a photo detector detects the filled condition of the bottle. After the bottle is filled, the buzzer sounds and the control program will again wait for 0.7secs, before moving to the next bottle, Until the limit switch signals, the feed motor, MI runs. while there are fixed rollers which carries the filled bottles. Motor, M2 keeps running after the process has been started, Solenoid Operated Controt ie Photoeye Detector Se To Bottle Filled Botties Outfeed Motor Drive Drive (Always ON During Process) Mt M2 Fig. 1: Automatic Bottle Filling SystemZunaib Ali - 09 Flow Chart- Fig.2: Automatic Bottle Filling System Flow Chart Mugadsa Iftikhar - 037 é é q zZunaib Ali - 09 Mugadsa Iftikhar - 03 Inputs and Outputs Used- |\Variable Na} Data Ty Memory All Initial Value |Varial Comments} ler BOOL_ KOXD.A VAR Buzer 2 |ro BOOL %OXD.1.6 vAR > Filled Bote _INsTO FB instance VAR fa JINSTi__FBinstance vaR ut BOOL —%GXD4.3 var * Light is BOOL %IKO.02 vaR > Limit Switeh Z| BOOL %OX0.1.0 vaR Feed Motor ie_|ua BOOL —OXD.11 VAR out Feed M a |re BOOL ——_sIKDO3 vaR + Photo Deter ia |st BOOL _SGXD.1.2 vAR + Solenoid Va fi |sTaRT Book DOOD VaR ag |stor ool O01 vaR —| nar BOOL %aX0.20 var Timer fa fr2 BOOL X01 VAR Timer 2 Observation- Once the start button is press ced the green light (L1) turns ON and remains ON until stop button is pressed. As light turns ON outfeed motor (M2) starts running, After M2 runs and if either limit switch (LS) has not signaled or filled bottle condition is fulfilled motor (M1) starts. After limit switch has signaled timer, TI gets activated. After Tl gives done (DN) signal and photoeye detector (PE) is disabled, solenoid valve gets in operation. As PE signals solenoid stops and buzzer (B1) sounds after which timer, T2 gets enabled which stops the process for 0.7 seconds. Once the filled bottle condition activated the cycle starts again. The ladder diagram was successfully checked in the GMWIN and all the prescribed conditions were observed completelyZunaib Ali - 09 Mugadsa Iftikhar - 03 Simulations * When Start Button is pressed Light L1, Motor M2 and Motor MI gets On/Started. woos |E Warectag karate PWR CPU 0 8Zunaib Ali - 09 Mugadsa Iftikhar - 03 © When photoeye detector is signaled, Solenoid valve is turned-OFF, and after some time Filled Bottle signal is made high and process is repeated again and new bottle i filled. ov 10 Bow LL Bow 12 ow 13 | 18700ms me ow 14 ov 15 ow 16 deooeoooooos