Professional Documents
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Manual
2021-22
Do’s
▪ Be punctual.
▪ Maintain discipline & silence.
▪ Keep the Laboratory clean and tidy.
▪ Enter Laboratory without shoes.
▪ Handle instruments with utmost care.
▪ Come prepared with Programs and learning materials.
▪ Follow the procedure that has been instructed.
▪ Return all the issued equipment’s properly.
▪ Get the signature on experiment result sheet daily.
▪ For any clarification contact faculty/staff in charge only.
▪ Shut down the power supply after the experiment.
Don’ts
▪ Avoid unnecessary chat or walk.
▪ Playing mischief in the laboratory is forbidden.
▪ Disfiguring of furniture is prohibited.
▪ Do not start the experiment without instructions.
▪ Avoid using cell phones unless absolutely necessary.
▪ Avoid late submission of laboratory reports.
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INTRODUCTION
A programmable Logic Controller (PLC) is a specialized computer used for the control and operation
of manufacturing process and machinery. It uses a programmable memory to store instructions and
execute functions including on/off control, timing, counting, sequencing, arithmetic, and data
handling. Programmable Logic Controllers (PLC) are used in almost every aspect of industry to
expand and enhance production. Where older automated systems would use hundreds or thousands of
electromechanical relays, a single PLC can be programmed as an efficient replacement. The
functionality of the PLCs has evolved over the years to include capabilities beyond typical relay
control. Sophisticated motion control, process control, distributive control systems, and complex
networking have now been added to the PLC’s functions. Therefore, PLCs provide many advantages
over conventional relay type of control, including increased reliability, more flexibility, lower cost,
communication capability, faster response time and convenience to troubleshoot.
ARCHITECHTURE OF PLC
A standardized set of PLC programming guidelines, set forth by the International Electro
technical Commission, that includes general PLC information, equipment and test requirements,
programming languages, user guidelines, and communication standards. IEC 61131-3 not only
describes the PLC programming languages themselves, but also offers comprehensive concepts and
guidelines for creating PLC projects.
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Declaration of variables
The IEC 61131-3 standard uses variables to store and process information. Variables correspond to
(global) flags or bit memories in conventional PLC systems. However, their storage locations no
longer need to be defined manually by the user (as absolute or global addresses), but they are managed
automatically by the programming system and each possess a fixed data type. IEC 61131-3 specifies
several data types (Bool, Byte, Integer). These differ, for example, in the number of bits or the use of
signs. It is also possible for the user to define new data types: user-defined data types such as
structures and arrays. Variables can also be assigned to a certain I/O address and can be battery backed
against power failure. Variables have different forms. They can be defined (declared) outside a POU
and used program-wide, they can be declared as interface parameters of a POU, or they can have a
local meaning for a POU. For declaration purposes they are therefore divided into different variable
types. All variables used by a POU have to be declared in the declaration part of the POU. The
declaration part of a POU can be written in textual form independently of the programming language
used. Parts of the declaration (input and output parameters of the POU) can also be represented
graphically.
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Emergency Stops:
It is recommended that emergency stop circuits be incorporated into the system for every machine
controlled by a PLC. For maximum safety in a PLC system, these circuits must not be wired into the
controller, but should be hardwired external to the PLC. The emergency stop switches should be
easily accessed by the operator and are generally wired into a master control relay (MCR) or a safety
control relay (SCR) that will remove power from the PLC I/O system in an emergency. MCRs and
SCRs provide a convenient means for removing power from the I/O system during an emergency
situation by de-energizing an MCR (or SCR) coil, power to the input (optional) and output devices is
removed. This event occurs when any emergency stop switch opens. However, the PLC continues to
receive power and operate even though all its inputs and outputs are disabled. The MCR circuit could
be extended by placing a PLC fault relay (closed during normal PLC operation) in series with any
other emergency stop conditions. This would cause the MCR circuit to drop the PLC I/O power in
case of a PLC failure (memory error, I/O communications error. etc.).
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Wiring Guidelines:
Power Input Wiring
Problem Description
Develop a program that will cause output D to go true when switch A and switch B are closed or when switch
C is closed.
Equipment used: Panasonic PLC & FPWinPro software
Truth Table:
Steps involved:
• To detect and monitor the switch A, B and, C continuously and change the output D accordingly.
Truth Table:
Steps involved:
• To detect and monitor button A, B, and C continuously and change the status of output D.
Conclusion:
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Problem Description
Design a motor controller that has a forward and a reverse button. The motor forward and reverse outputs will
only be on when one of the buttons are pushed. When both buttons get pushed the motor will not work.
Truth Table:
Steps involved:
• To monitor forward and reverse buttons, and rotate the motor according the switch status.
Problem Description
Procedure:
Pneumatic circuit diagram
• Both double-acting cylinders are controlled by 5/2 directional control impulse valves.
• The valves are equipped with visual display and manual override.
• Valve 1 has the solenoid coils designated Y1 and Y2, valve 2 those with Y3 and Y4.
• When signal voltage is applied to the solenoid coils Y1 and Y3, the cylinders extend, when voltage is
applied to Y2 and Y4 the cylinders retract.
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• Both cylinders have cylinder switches with visual displays mounted in their end positions, these are
designated B1 to B4.
• The extension speed of both cylinders can be infinitely adjusted with a one-way flow control valve.
Problem Description
Consider the design of a burglar alarm for a house. When activated an alarm and lights will be activated to
encourage the unwanted guest to leave. This alarm be activated if an unauthorized intruder is detected by
window sensor and a motion detector. The window sensor is effectively a loop of wire that is a piece of thin
metal foil that encircles the window. If the window is broken, the foil breaks breaking the conductor. This
behaves like a normally closed switch. The motion sensor is designed so that when a person is detected the
output will go on. As with any alarm an activate/deactivate switch is also needed. The basic operation of the
alarm system, and the inputs and outputs of the controller are itemized here
The next step is to define the controller equation. In this case the controller has 3 different inputs, and a single
output, so a truth table is a reasonable approach to formalizing the system. A Boolean equation can then be
written using the truth table .Of the eight possible combinations of alarm inputs, only three lead to alarm
conditions.
Conclusion :
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Problem Description
One open tank is installed in the plant of which liquid level is to be controlled. When level reaches
the Level Low, Outlet flow is blocked and inlet flow is allowed until high level is achieved. And
when Level High is detected, outlet flow is allowed and inlet flow is blocked.
Problem Diagram
Steps involved:
• To detect high and low level of liquid in the tank, two level switches are used which gives output
in digital terms, that is when corresponding levels are detected, it gives output high otherwise
remain low.
• To control level of this system, Single Acting piston valve can be used which has two states, either
fully open or fully close.
• Low Level Switch is mounted at the bottom of the tank and Level High switch mounted at the side
upper most position.
• When inputs are detected, output to Control Valve has to be latched in order to continuously fill or
empty the system.
• Master start/stop is also provided to shut down or start the entire process.
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Ladder diagram
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Components required
Scope/Applications
Circuit Diagram
] Marks
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Flow Chart
[ ] Marks
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Problem Description
When a part is placed on the conveyor at position 1, and when a start button is pressed it moves to
position 2. Upon reaching position 2, it stops for the stamping operation to take place. After stamping
it automatically moves to position 3. It stops at position 3, where the part is removed manually from
the conveyor. Assume only one part is on the conveyor at a time. Add limit switches, interlocks, push
buttons, etc. as required.
Problem Diagram
Problem Solution
Logic Diagram:
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Ladder diagram
Components required
▪ Rexroth training Kit -1 (L10 or L20)
Indralogic software
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Scope/Applications
Following are the major applications it can be used for
→Postal system
→Banking
→Barcode stamping
Circuit Diagram
[ ] Marks
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Flow Chart
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Working Principle
This ladder logic is for PLC automation of material stamping using conveyor belt. When an object is placed on
conveyor belt on position 1 the belt moves forward. this happens till the belt reaches position 2 where its
stopped. The stamping then takes place which is controlled by sensors to control motion of stamper. Once the
stamping is done the belt is moved to position 3 automatically where the part is removed manually. [ ]
Marks
Code and connections [ ] Marks
ShownCompleted
ErrorsExecuted
Assessment for 5 marks (please tick one)
o Poor → 0 ~ 2 marks
o Good → 3 ~ 4 marks
o Excellent → 5 marks
Note: Refer to rubrics for more details!
Problem Description
Develop a PLC program that will control a miniature set of traffic lights. These lights will go through a normal
sequence, but will have pedestrian cross walk buttons that will activate a cross walk signal when pressed.
When done the student should understand the design and implementation of time dependent control circuits.
Process Description:
We want to develop a controller for a set of traffic lights that is at the cross of Main St. and a less used Cross
Rd. The lights under two possible sequences as shown below. In the normal sequence the green for cross is
shorter with no cross walk light. If a cross walk button is pushed while the Main light is green or yellow the
Cross green light will be on longer with a walk sign.
Procedure:
1. Draw a state transition diagram for the traffic lights given the process description below.
2. Write the ladder logic model for the state transition diagrams.
3. Develop an exhaustive test table that will test all of the possible transition states for the traffic lights.
Ladder diagram
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▪ Components required
▪ Rexroth training Kit -1 (L10 or L20)
▪ Indralogic software
Scope/Applications
→emergency systems
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Circuit Diagram
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Flow Chart
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Working Principle
The ladder logic is for automating signal transition from green to yellow for vehicles and pedestrians. The signal
starts of with cross green which is for 10s after which cross yellow signal is on for 4s. After this the main green
signal goes high for 20s which is then followed by main yellow which of 4s. During the main green or main yellow
signal if anyone presses the cross-walk button, in the next cycle the cross green is for 20s instead of 10. [ ]
Marks
Problem Description
Objects are moving on a conveyor belt 1. When an empty box is detected, conveyor belt starts and 5pcs are
packed in a box. When box is filled, it is carried to the storage area via conveyor belt 2. Implement
automation of this process in PLC using Ladder Diagram programming language.
Problem Diagram
Problem Solution
• Use proximity switches to detect moving objects on the conveyor belt 1 and to detect an empty box
on conveyor belt 2.
• Use timer such that when 5pcs are detected, conveyor runs for a while and stops when 5th object is
finally collected in the box. Assume time by calculating conveyor belt speed.
• When number of parts to be packed are detected timer is activated. When timer is over, it stops the
conveyor until next empty box is detected.
▪ Components required
▪ Rexroth training Kit -1 (L10 or L20)
▪ Indralogic software
Scope/Applications
→Product Shipping
→Food industries
→Healthcare
Circuit Diagram
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Flow Chart
[ ] Marks
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Problem Description
Whenever a part is placed on the drilling table, pneumatic clamper clamps the part and drilling process is
done. When drilling is done, clamper releases the part by releasing pressure. When another part is
detected, the process is repeated. Implement this in PLC using Ladder Diagram programming language.
Problem Diagram
Problem Solution
• Set lower and upper limit of a motor to stop and start the drilling process. This is done for precise
drilling and to obtain uniformity.
• Pressure operated clamping device is used to hold the objects firmly. This is operated by 20psig
air supply which is provided when an object is detected.
• Limit detection object is placed on the motor to detect upper and lower limit by the switches.
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Ladder diagram
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Scope/Applications
Circuit Diagram
[ ] Marks
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Flow Chart
[ ] Marks
Department of Automation and Robotics
Problem Description
One open tank is installed in the plant of which liquid level is to be controlled. When level reaches the
Level Low, Outlet flow is blocked and inlet flow is allowed until high level is achieved. And when Level
High is detected, outlet flow is allowed and inlet flow is blocked.
Problem Diagram
Problem Solution
• To detect high and low level of liquid in the tank, two level switches are used which gives output
in digital terms, that is when corresponding levels are detected, it gives output high otherwise
remain low.
• To control level of this system, Single Acting piston valve can be used which has two states, either
fully open or fully close.
• Low Level Switch is mounted at the bottom of the tank and Level High switch mounted at the
side upper most position.
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• When this inputs are detected, output to Control Valve has to be latched in order to continuously
fill or empty the system.
• Master start/stop is also provided to shut down or start the entire process.
Logic Diagram:
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▪ Components required
▪ Rexroth training Kit -1 (L10 or L20)
▪ Indralogic software
Scope/Applications
Problem Description
A vehicle shown in Figure below carries two different objects with different sizes. Initially, the vehicle waits at
the mid-point of the system.
• When a large-sized object is placed on the vehicle, it moves backward up to the 1st drop point. After
reaching to the point, vehicle waits until the object on is removed. Then, vehicle returns back to the mid-
point.
• When a small-sized object is placed on the vehicle, it moves forward up to the 2nd drop point. After
reaching to the point, vehicle waits until the object on is removed. Then, vehicle returns back to the mid-
point.
• During the movement, if an object comes in front of the vehicle stops with the help of a photo sensor, then a
buzzer is turned on to indicate the situation. When the object is removed, the vehicle continues its
movement.
• Red LED is on when the object is detected in front of the vehicle. The green LED indicates that the
vehicle reached 1st drop point, and yellow LED indicates that the vehicle reached to the 2nd drop point.
Construct a PLC logic for this system.
Ladder Diagram:
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Scope/Applications
→Transport
→Vehicle shipment
Flow Chart
[ ] Marks
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Problem Description
( Station1 / Station2 / Station3)
Problem Diagram
Problem Solution
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Logic Diagram:
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Components required
Scope/Applications