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ME6405
Section Objectives:
Before the invention of the Programmable Logic Controller
(PLC), most industrial control was done using relay control
panels.
Switches and relays can be arranged in circuits to make
logical decisions. Output from these circuits can be used to
drive loads such as motors, heaters, or electromagnetic
coils. A relay control panel is comprised of a single to
thousands of these circuits.
In this Section, relay control panels will be presented.
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ME6405
2
1
Pins 1 and 2 are normally closed since they are connected when the
switch is off. T Pins 1 and 2 are not connected when the switch is on.
Pins 1 and 3 are normally open since they are not connected when the
switch is off. Pins 1 and 3 are connected when the switch is on.
(Note: Although this is a toggle switch, this switch can symbolize any type
of input source such as push button switches, sensors, power supplies,
etc. in this lecture.)
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ME6405
Coil off
Coil on
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ME6405
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ME6405
V+
Switch 1
Coil
2
1
3
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ME6405
Switch 1
Coil
2
1
3
Switch 1
Coil
2
1
3
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ME6405
V+
Switch 1
Switch 2
Coil
2
2
1
1
3
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ME6405
Switch 1
Switch 2
Coil
2
2
1
1
3
Switch 1
Switch 2
Coil
2
2
1
1
3
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ME6405
Switch 1
Switch 2
Coil
2
2
1
1
3
Switch 1
Switch 2
Coil
2
2
1
1
3
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ME6405
Relay Logic : OR
Using two switches, a logical OR operation can
be constructed. An example is given below:
Switch 1 OR Switch 2 = Coil
V+
Switch 1
2
Coil
1
3
Switch 2
2
1
3
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ME6405
Relay Logic : OR
Switch 1 off OR Switch 2 off = Coil off
V+
Switch 1
2
Coil
1
3
Switch 2
2
1
3
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ME6405
Relay Logic : OR
Switch 1 on OR Switch 2 off = Coil on
V+
Switch 1
2
Coil
1
3
Switch 2
2
1
3
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ME6405
Relay Logic : OR
Switch 1 off OR Switch 2 on = Coil on
V+
Switch 1
2
Coil
1
3
Switch 2
2
1
3
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ME6405
Relay Logic : OR
Switch 1 on OR Switch 2 on = Coil on
V+
Switch 1
2
Coil
1
3
Switch 2
2
1
3
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ME6405
Switch 1
2
V+
V+
Coil
3
2
Switch 2
1
2
1
3
3
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ME6405
V+
Switch 1
2
V+
V+
Coil
3
2
Switch 2
1
2
1
3
3
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ME6405
V+
Switch 1
2
V+
V+
Coil
3
2
Switch 2
1
2
1
3
3
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ME6405
V+
Switch 1
2
V+
V+
Coil
3
2
Switch 2
1
1
3
3
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ME6405
V+
Switch 1
2
V+
V+
Coil
3
2
Switch 2
1
1
3
3
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ME6405
GeorgeW.
W.Woodruff
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ME6405
GeorgeW.
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ME6405
Section Objectives:
Basic PLC Components needed to replace relay control
panels will be presented. These include:
Isolated Power Supply
Micro-controller
Memory
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ME6405
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ME6405
GeorgeW.
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ME6405
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ME6405
WORK Memory
Memory is RAM
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ME6405
Memory is RAM
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ME6405
GeorgeW.
W.Woodruff
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ME6405
Section Objectives:
Initially PLCs were used to directly replace relay control
panels. To directly replace relay control panels based on
mechanical relays with PLCs based on a micro-controller
presented challenges. These challenges and solutions will
be discussed.
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ME6405
I1,I2, ,Im
Q1
I1,I2, ,Im
Q2
.
.
.
I1,I2, ,Im
Qn
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ME6405
Q1 changes at t1
Q2 changes at t1
.
.
.
I1,I2, ,Im changes at t0
Qn changes at t1
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ME6405
Q1 changes at t1
Q2 changes at t2
.
.
.
I1,I2, ,Im changes at t0
Qn changes at tn
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Difference 2:
Relay Control Panel Since this is made from analogue components. It is possible to replace
a logic section without stopping execution of other logic sections if wired correctly.
PLC This is made with a digital micro-controller. The micro-controller must be halted to
replace a logic section. All other logic sections will stop operation.
Difference 3:
Relay Control Panel Since parallel execution of logic sections, all outputs are a function of
one set of inputs.
PLC Since serial execution of logic sections, all outputs may not be a function of one set of
inputs. (example: input I2 may change as the micro-controller is processing Logic section
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Q2 are based
onof
different
inputs)
2. Therefore
QW.
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1 and
ME6405
Steps:
Warm Restart
scan cycle
User Program
ME6405
To Minimize Difference 2:
If a part of the user program is replaced, the new part is written first to LOAD memory. During
step 5, PLC System Processes, the new part is copied into WORK memory from LOAD
Memory. During the next scan cycle, the new part of the user program will be executed.
To Minimize Difference 3:
If the programmer uses the inputs stored in the Process Input Image, the user program will
have access to the same inputs per scan cycle. Also if the programmer, writes outputs to
the Process Output Image, all the outputs will be updated simultaneously during step 4,
Update Process Output Image.
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ME6405
GeorgeW.
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ME6405
Section Objectives:
The biggest transition from relay control panels to PLCs
was the transition from the hard wired relay logic to logic
defined by user program. In order to allow established relay
logic users to program the PLC, a visual programming
language that looks like a relay control panel was created.
This visual programming language is called Ladder Logic.
In this section, basic Ladder Logic will be presented.
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ME6405
Memory Area
Notation
Byte Address
Bit Number
Memory Area
Notation
Size of Addressed
Memory Notation
Byte Address
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ME6405
Memory Area
I
Marker Memory
PI
PQ
DB
ME6405
Byte (8 bits)
Byte Address:
Each Memory Area is addressed in one byte increments
starting at byte 0.
Bit Number:
MSBit is 7 and LSBit is 0
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ME6405
M1.3
(Note: only bit 3 of
Marker Area byte 1)
MB0
Byte 1
Byte 2
MW1
Byte 3
Byte 4
MD3
Byte 5
Byte 6
MD4
Byte 7
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ME6405
PI2.5
(Note: only bit 5 of
Peripherial Input Area byte 2)
Byte 1
PIB1
Byte 2
Byte 3
Byte 4
Byte 5
PID4
Byte 6
Byte 7
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ME6405
Power Rail
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ME6405
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ME6405
Switch 1
Coil
2
1
3
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ME6405
Switch 1
V+
V+
Coil
Virtual Input
Relay at I0.0
Virtual Output
Relay at Q0.0
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ME6405
I0.0
Q0.0
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ME6405
Switch 1
Switch 2
Coil
2
2
1
1
3
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ME6405
Switch 1
V+
2
1
Inside PLC
1
3
V+
V+
Coil
Virtual Input
Relay at I0.0
Switch 2
3
2
Virtual Input
Virtual Output
Relay at Q0.0
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Relay
at I0.1School
ME6405
I0.1
Q0.0
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ME6405
Ladder Logic : OR
Switch 1 OR Switch 2 = Coil
From Relay Logic:
V+
Switch 1
2
Coil
1
3
Switch 2
2
1
3
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ME6405
Switch 1
V+
2
1
Inside PLC
1
3
V+
V+
Coil
Virtual Input
Relay at I0.0
Switch 2
V+
2
Virtual Input
Virtual Output
Relay at Q0.0
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Relay
at I0.1School
ME6405
Q0.0
I0.1
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ME6405
V+
Switch 1
2
V+
V+
Coil
3
2
Switch 2
1
2
1
3
3
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ME6405
Virtual Input
Relay at I0.0
Switch 1
2
1
Virtual Input
Relay at I0.0
V+
V+
V+
Virtual Output
Relay at Q0.0
2
V+
Coil
Switch 2
2
1
(Note: Wired to
PLC Output Pin
Associated with
Virtual Output
Relay PQ0.0)
ME6405
I0.1
I0.0
I0.1
Q0.0
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ME6405
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ME6405
Section Objectives:
A micro-controller can be used for more than relay logic
with virtual relays. Ladder logic has components that take
advantage of the micro-controller. These components can
be categorized as follows: bit logic,comparator, converter,
counter, data base calls, jumps, integer functions, floating
point functions, move, program control, shift/rotate, status
bits, timers, and word logic.
It is impossible to cover all of the components in one
lecture. This lecture will first explain formatting of
constants. Then, only a few categories and examples of
components will be shown.
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ME6405
Constants
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ME6405
Constants
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ME6405
Constants
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ME6405
Constants
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Bit Logic
Available Bit logic components:
Normally Closed Switch
Output Coil
Midline Output
Set Coil
Reset Coil
Immediate Read
Immediate Write
Bit Exclusive OR
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Description:
Set Coil is executed only if power flows to the coil. When executed, the specified
<address> of the element is set to "1". It will remain set even if power is removed
from the coil.
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ME6405
Description:
Reset Coil is executed only if power flows to the coil. When executed, the
specified <address> of the element is reset to "0". No power flow to the coil has
no effect and the state of the element's specified address remains unchanged.
(Note: can be used to reset timers and counters)
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ME6405
Q0.0
S
I0.1
Q0.0
R
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ME6405
Comparator
Available Comparator components (Note: Integer is Word, Double Integer is
Double Word)
Integer: Equal to
Real: Equal to
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ME6405
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ME6405
MW0
CMP
== I
IN1
MW2
IN2
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ME6405
Jumps
Available Jump components (Note: called Logic control in Step 7 Help)
Label
Unconditional Jump
Conditional Jump
Not conditional Jump
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ME6405
END
JMP
Components
Components
END
Q0.0
I0.1
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ME6405
Integer Math
Available Integer Math components:
(Note: Integer is Word, Double Integer is Double Word)
Integer: Add
Integer: Subtract
Integer: Multiply
Integer: Divide
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Description:
IN1 and IN2 are added and the result is stored in OUT when power is
applied to EN . Power flows out of EN0 when power is applied to EN unless
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the addition
results
in overflow. of Mechanical Engineering, Georgia Tech
ME6405
ADD_I
EN
5
IN1
MW0
IN2
EN0
OUT
MW2
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ME6405
Move
Available Move components:
Move
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ME6405
Move example:
Description:
IN is moved to Out and power flows out of EN0 when power is applied to
EN.
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ME6405
Move example:
Example:
Move 5 to MW2.
MOVE
EN
EN0
IN1
OUT
MW2
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Timer
Available Timer components:
Pulse S5 Timer
On-Delay S5 Timer
Off-Delay S5 Timer
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ME6405
Description:
A power transition from OFF to ON on S will restart the timer. Power flows
from Q while timer is running. The timer will run for a preset time TV.
(Note: 256
timers
allowed
inSchool
S7 314C-PtP
PLC)Engineering, Georgia Tech
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George W. Woodruff School of Mechanical Engineering, Georgia Tech
ME6405
Timer example:
Example:
Switch 1 connected to Input 0.0
Coil is connected to Output 0.0
Turn on coil for 10 seconds if Switch 1 is turned on.
T0
I0.0
Q0.0
S_EXt
S5T#10s
TV
BI
BCD
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ME6405
Word Logic
Available Word Logic components:
AND Word
OR Word
OR Double Word
XOR Word
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Description:
IN1 AND IN2 is stored in OUT when power is applied to EN . Power flows
out of EN0 when power is applied to EN unless the addition results in
overflow.
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ME6405
WAND W
EN
MW0
IN1
MW2
IN2
EN0
OUT
MW4
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ME6405
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ME6405
Section Objectives:
In this section two example ladder logic programs will be
given.
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ME6405
Example 1 :
Switch 1 connected to Input 0.0
Coil connected to Output 0.0
If Switch 1 is on then turn on and off a coil at 2 second intervals
(Note: 2 second interval means a period of 4 seconds and 50% Duty
cycle).
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ME6405
Example 1 (Continued)
Time: Scan cycle right before t = 0s
User Action : None
T0
I0.0
M0.0
S_EXt
S5T#2s
Q0.0
S
Q
TV
BI
R BCD
T1
I0.0
Q0.0
S_EXt
S5T#2s
M0.0
S
Q
TV
BI
R BCD
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Example 1 : Continued
Time:Scan cycle at t = 0
User Action: User turns Switch 1 on
T0
I0.0
M0.0
S_EXt
S5T#2s
S
Q
TV
BI
R BCD
Q0.0
(Note:
Time left: 2 s)
T1
I0.0
Q0.0
S_EXt
S5T#2s
M0.0
S
Q
TV
BI
R BCD
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Example 1 : Continued
Time: Scan cycle right before t = 2s
User Action: None
T0
I0.0
M0.0
S_EXt
S5T#2s
S
Q
TV
BI
R BCD
Q0.0
(Note:
Time left: ~0)
T1
I0.0
Q0.0
S_EXt
S5T#2s
M0.0
S
Q
TV
BI
R BCD
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Example 1 : Continued
Time: Scan cycle at t = 2 s
User Action: None
I0.0
M0.0
S_EXt
S5T#2s
S
Q
TV
BI
R BCD
Q0.0
(Note:
Time left 0 s)
T1
I0.0
Q0.0
S_EXt
S5T#2s
S
Q
TV
BI
R BCD
M0.0
(Note:
Time left: 2 s)
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Example 1 : Continued
Time: Scan cycle right after t = 2 s
User Action: None
T0
I0.0
M0.0
S_EXt
S5T#2s
Q0.0
S
Q
TV
BI
R BCD
T1
I0.0
Q0.0
S_EXt
S5T#2s
S
Q
TV
BI
R BCD
M0.0
(Note:
Time left: 2 s 1
scan cycle time)
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Example 1 : Continued
Time: Scan cycle right before t = 4 s
User Action: None
T0
I0.0
M0.0
S_EXt
S5T#2s
Q0.0
S
Q
TV
BI
R BCD
T1
I0.0
Q0.0
S_EXt
S5T#2s
S
Q
TV
BI
R BCD
M0.0
(Note:
Time left: ~0 s)
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Example 1 : Continued
Time: Scan cycle at t = 4 s
User Action: None
T0
I0.0
M0.0
S_EXt
S5T#2s
Q0.0
S
Q
TV
BI
R BCD
T1
I0.0
Q0.0
S_EXt
S5T#2s
S
Q
TV
BI
R BCD
M0.0
(Note:
Time left: 0 s)
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Example 1 : Continued
Time: Scan cycle right after t = 4 s
User Action: None
I0.0
M0.0
S5T#2s
S
Q
TV
BI
R BCD
(Note:
Time left: 2 s)
T1
I0.0
Q0.0
S_EXt
S5T#2s
M0.0
S
Q
TV
BI
R BCD
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Example 1 : Continued
Time: Some time later
User Action: User turns Switch 1 off
T0
I0.0
M0.0
S_EXt
S5T#2s
Q0.0
S
Q
TV
BI
R BCD
T1
I0.0
Q0.0
S_EXt
S5T#2s
M0.0
S
Q
TV
BI
R BCD
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Example 1 :
Comments:
As this example illustrates, consistent timing is difficult to achieve with a
PLC due to the scan cycle. This is the reason why PLCs are not used to
control systems with very fast time constants such as CNC machines,
chemical mixers, etc.
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Example 2 :
Switch 1 connected to Input 0.0
A Hall effect switch is connected to Input 0.1
(Note: a Hall effect switch will turn on when a magnetic object comes
in close proximity)
The motor for a conveyer belt is connected to Output 0.0
(Note: As previously mentioned, a coil can be any load such as a
motor during these lectures.)
If Switch 1 is turned on, the conveyer belt will transport 1000 magnetic
SHAFTS to Georgia Tech Students. Switch 1 must be turned off then on to
send another 1000 magnetic SHAFTS. The hall affect switch is positioned
right under the conveyer belt and can be used to count the SHAFTS as
they pass by.
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Example 2 (Continued)
Time: Scan cycle right before t = 0s
Actions : no part near hall effect switch
I0.0
M0.0
Move
Q0.0
EN
0
Q0.0
S
EN0
IN1 OUT
MW1
M0.0
S
I0.0
M0.0
R
Q0.0
CMP
== I
I0.1
M0.1
1001
IN1
MW1
IN2
EN
1
I0.1
M0.1
ADD_I
MW1
EN0
IN1
IN2 OUT
MW1
M0.1
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R
ME6405
Example 2 (Continued)
Time: Scan cycle at t = 0s
Actions : Switch 1 is turned on,
no SHAFT near hall effect switch
I0.0
M0.0
Move
Q0.0
EN
0
Q0.0
S
EN0
IN1 OUT
MW1
M0.0
S
I0.0
M0.0
R
Q0.0
CMP
== I
I0.1
M0.1
1001
IN1
MW1
IN2
EN
1
I0.1
M0.1
ADD_I
MW1
EN0
IN1
IN2 OUT
MW1
M0.1
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Example 2 (Continued)
Time: Scan cycle right after t = 0s
Actions : no SHAFT near hall effect switch
I0.0
M0.0
Move
Q0.0
EN
0
Q0.0
S
EN0
IN1 OUT
MW1
M0.0
S
I0.0
M0.0
R
Q0.0
CMP
== I
I0.1
M0.1
1001
IN1
MW1
IN2
EN
1
I0.1
M0.1
ADD_I
MW1
EN0
IN1
IN2 OUT
MW1
M0.1
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Example 2 (Continued)
Time: t = t1
Actions : SHAFT approaches hall effect switch, 1 is added to MW1
I0.0
M0.0
Move
Q0.0
EN
0
Q0.0
S
EN0
IN1 OUT
MW1
M0.0
S
I0.0
M0.0
R
Q0.0
CMP
== I
I0.1
M0.1
1001
IN1
MW1
IN2
EN
1
I0.1
M0.1
ADD_I
MW1
EN0
IN1
IN2 OUT
MW1
M0.1
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R
ME6405
Example 2 (Continued)
Time: t = t1 + 1 scan cycle
Actions : SHAFT passes over hall effect switch
I0.0
M0.0
Move
Q0.0
EN
0
Q0.0
S
EN0
IN1 OUT
MW1
M0.0
S
I0.0
M0.0
R
Q0.0
CMP
== I
I0.1
M0.1
1001
IN1
MW1
IN2
EN
1
I0.1
M0.1
ADD_I
MW1
EN0
IN1
IN2 OUT
MW1
M0.1
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R
ME6405
Example 2 (Continued)
Time: t = t1 + 2 scan cycle
Actions : no SHAFT near hall effect switch
I0.0
M0.0
Move
Q0.0
EN
0
Q0.0
S
EN0
IN1 OUT
MW1
M0.0
S
I0.0
M0.0
R
Q0.0
CMP
== I
I0.1
M0.1
1001
IN1
MW1
IN2
EN
1
I0.1
M0.1
ADD_I
MW1
EN0
IN1
IN2 OUT
MW1
M0.1
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R
ME6405
Example 2 (Continued)
Time: t = t1 + 3 scan cycle
Actions : no SHAFT near hall effect switch
I0.0
M0.0
Move
Q0.0
EN
0
Q0.0
S
EN0
IN1 OUT
MW1
M0.0
S
I0.0
M0.0
R
Q0.0
CMP
== I
I0.1
M0.1
1001
IN1
MW1
IN2
EN
1
I0.1
M0.1
ADD_I
MW1
EN0
IN1
IN2 OUT
MW1
M0.1
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R
ME6405
Example 2 (Continued)
Time: t = t2
Actions : the 1001th SHAFT approaches hall effect switch (so 1000 have been delivered)
I0.0
M0.0
Move
Q0.0
EN
0
Q0.0
S
EN0
IN1 OUT
MW1
M0.0
S
I0.0
M0.0
R
Q0.0
CMP
== I
I0.1
M0.1
1001
IN1
MW1
IN2
EN
1
I0.1
M0.1
ADD_I
MW1
EN0
IN1
IN2 OUT
MW1
M0.1
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R
ME6405
Example 2 (Continued)
M0.0
Move
Q0.0
EN
0
Q0.0
S
EN0
IN1 OUT
MW1
M0.0
S
I0.0
M0.0
R
Q0.0
CMP
== I
I0.1
M0.1
1001
IN1
MW1
IN2
EN
1
I0.1
M0.1
ADD_I
MW1
EN0
IN1
IN2 OUT
MW1
M0.1
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ME6405
Example 2 (Continued)
Time: t = t2+ 1 scan cycle
Actions : the conveyer is stopped. Switch 1 must be turned off and on to deliver 1000 more
I0.0
M0.0
Move
Q0.0
EN
0
Q0.0
S
EN0
IN1 OUT
MW1
M0.0
S
I0.0
M0.0
R
Q0.0
CMP
== I
I0.1
M0.1
1001
IN1
MW1
IN2
EN
1
I0.1
M0.1
ADD_I
MW1
EN0
IN1
IN2 OUT
MW1
M0.1
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ME6405
Example 2 :
Comments:
This and the previous example illustrates that the serial nature of the PLC
micro-controller can still affect program execution.
Also, this program can be simplified using an positive edge detection coil.
This was not done because the positive edge detection coil was not an
example in Section 5.
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ME6405
So far we have looked at topics applicable to all PLCs. Further Study Should focus
on:
Topics applicable to some but not all PLCs:
Interrupts
A/D
Counters
Function Blocks
Communication Protocol:
Profibus
How to use communications to communicate with other PLCs,
smart actuators and sensors, etc
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