DEPARTMENT OF MECHATRONICS AND BIOMEDICAL

ENGINEERING
AIR UNIVERSITY, ISLAMABAD

MANUFACTURING AUTOMATION
(MT451-L)

Submitted to:MaamAnamMaqbool
Submitted by:M Abdul Basit
Registration ID:170615

DEPARTMENT OF MECHATRONICS AND BIOMEDICAL ENGINEERING

AIR UNIVERSITY, ISLAMABAD
 LAB # 1
Introduction to Industrial Automation and PLC’s

Industrial Automation:

Industrial Automation is the hybrid field in which there is a use of Control systems and
Robotics and processes are automated based on the complexity of process thus reducing
human intervention and increasing efficiency and flexibility of processes. Industrial
automation includes automation applied on industrial processes or in industries.

Types of Industrial Automation:

Following are the types of industrial automation:

 Fixed Automation
 Programmable Automation
 Integrated Automation

Advantages of Industrial Automation:

Following are the advantages of industrial automation:

 High Productivity
 High Quality
 High Flexibility
 High Information Accuracy
 High safety

Programmable Logic Controller:

A digitally operating electronic apparatus, which uses a programming memory for the
internal storage of instructions for implementing specific functions.

Advantages of PLC:

 Less Wiring
 Wiring between devices and relay contacts are done in the PLC program
 Easier and faster to make changes
  Trouble shooting aids make programming easier and reduce downtime.
 Relatable components

Major Components of PLC:

1. Power Supply: Provides the voltage needed to run the primary PLC components.
2. I/O Modules: Provides signal conversion and isolation between the internal logic-
level signals inside the PLC and the field’s high-level signal.
3. Processor: Provides intelligence to the command and govern the activities of the
entire PLC systems.
4. Programming Device: Used to enter the desired program that will determine the
sequence of operation and control of process equipment or driven machine.

Selecting a PLC Criteria:

 Number of logical inputs and outputs

 Memory
 Number of special I/O modules
 Scan Time
 Communications
 Software

PLC Status Indicators:

 Power On
 Run Mode
 Programming mode
 Fault
 LAB # 2

Objective:

To understand the basics of Industrial Automation and PLC’s

Introduction:

LogixPro software:

LogixPro is a PLC simulator that is particularly geared toward Rockwell’s RSLogix 500 software.
There is no need for any PLC hardware when using the simulator. The keyed edition of LogixPro,
that is part of thecourse materials, provides animated process simulations, including an I/O simulator
with changeable switch types, output indicators, thumbwheel switches and a BCD digital readout.
Several process animations are also included and we will be working with several of them in future
homework labs.

The LogixPro Interface:

Figure shows the LogixPro environment after the software is initially started. There is a simulation
where the project window should be and that there is an animated help wizard on the screen. If you
would like to hide the animated help wizard, right click on him and select Hide. The Online/Offline
tool box has no functionality except for the Online/Offline dropdown box and this dropdown box is
not really needed.

Click on the Simulations menu to drop down the menu as shown in above Figure. These simulations
will only function with the keyed version of the LogixPro software. These simulations have no function
until you write PLC ladder logic to control them. When you are finished exploring the available
simulations select the I/O Simulator, then drag the window pane divider to view the I/O Simulator as
shown in Figure below.
Dragging the window pane divider in LogixPro is a-bit odd and does not always act like a normal
Windows application. Have patience if at first you don’t succeed.

To display the project window, click the close button ‘X’ of the simulator window. The close button
will toggle the window between project view and simulator view.

Enter a Rung of Ladder Logic:

1. Make the ladder editor window the active window.

2. The very first rung of a LogixPro ladder diagram cannot be dragged into the editor and
dropped.
3. To insert the first blank rung simply click the Insert Rung button in the tool bar and the new
rung will appear. After the first rung is inserted, other rungs can be dragged into the editor
window.
4. Drag an Examine if Closed (XIC) instruction onto the rung.
5. Drag an Output Energize (OTE) instruction onto the rung. Simply drop the OTE at the target
to the right of the XIC and it will be placed against the right power rail.
6. To add addresses to the instructions, double click the instruction and type the address into the
input field. Address the XIC instruction to: I:1/0 and the OTE instruction to O:2/0.
7. Instruction descriptions cannot be added but symbols can. To enter a symbol, right click on
the instruction and select Edit Symbol from the pop-up menu. Type a descriptive symbol in
the input field. A total of 28-characters is allowed to be entered in this field. Assign any
symbol you want to the instructions.
8. When you are finished your screen, it should look similar to the one shown in Figure below.

9. Click the Toggle button in the upper right corner of the Instruction Tool Bar. The Instruction
Tool Bar will change to display the PLC Panel as shown in Figure 7.
 10. In order to run a program, it must be downloaded to the PLC. Click the Download button in the PLC
Panel. The screen will momentarily flicker to simulate that the program is being downloaded.
11. Click the RUN radio button. This will place the PLC in the run mode.
12. Click on the switch addressed to I:1/0 in the I/O Simulator. The switch should close and the indicator
light addressed to O:2/0 should light.
13. In the ladder logic editor, instead of the instructions being highlighted to show power flow, the
addresses will glow yellow to show power flow.

Conclusion:

In this lab we learned the basics of Logixpro and made our first rung which was just a simple push
button.
 LAB # 3
Implementation of LOGIC Gates

Objective:

1. To understand he operation of OTE, XIC and XIO and simulate the given tasks in Allen Bradley PLC.

Abstract:

In this lab we have learnt about the basic instructions used in PLC programming. We implemented different gates
using these instructions in PLC. These gates were used in future labs in implementing the industrial automation
logic.

Tasks Implementation:

AND Gate:

AND Gate is an electrical circuit that combines two signals so that the output is HIGH when both signals are
present. Mathematical notation for AND Gate is:

𝑿 = 𝑿. 𝑿 = 𝑿𝑿

Below is the truth table for AND Gate:

A B X

0 0 0

0 1 0

1 0 0

1 1 1
Ladder Logic implementation is as follows:

OR Gate:

OR Gate is an electrical circuit that combines two signals so that the output is LOW when both signals are
absent. Mathematical notation for OR Gate is:

𝑿=𝑿+𝑿

Below is the truth table for OR Gate:

A B X

0 0 0

0 1 1
 1 0 1

1 1 1

Ladder logic for OR gate is as follows:

NAND Gate:

NAND Gate is an electrical circuit that combines two signals so that the output is LOW when both signals are
PRESENT. It is the complement of AND Gate. Mathematical notation for NAND Gate is:

𝑿𝑿𝑿𝑿𝑿 = 𝑿 + 𝑿
𝑿=𝑿 𝑿

Below is the truth table for NAND Gate:

A B X
 0 0 1

0 1 1

1 0 1

1 1 0

Ladder logic for NAND Gate is as follows:

NOR Gate:

NOR Gate is an electrical circuit that combines two signals so that the output is HIGH when both signals are
ABSENT. It is the complement of OR Gate. Mathematical notation for OR Gate is:

𝑿𝑿𝑿+
𝑿=𝑿 𝑿𝑿𝑿𝑿𝑿𝑿 = 𝑿𝑿
𝑿

Below is the truth table for OR Gate:

A B X

0 0 1
 0 1 0

1 0 0

1 1 0

Ladder logic for NOR Gate is as follows:

XNOR Gate:

XNOR Gate is an electrical circuit that combines two or more signals so that the output is HIGH when all signals
are HIGH or when all signals are LOW. Mathematical notation for OR Gate is:

𝑿𝑿𝑿𝑿𝑿
𝑿 = 𝑿𝑿 + 𝑿

Below is the truth table for XNOR Gate:

A B X

0 0 1
 0 1 0

1 0 0

1 1 1

Ladder logic of XNOR gate is as follows:

XOR Gate:

XOR Gate is an electrical circuit that combines two or more signals so that the output is HIGH when either signal
is HIGH or LOW. Mathematical notation for OR Gate is:

𝑿 = (𝑿 + 𝑿). (𝑿𝑿𝑿𝑿+
𝑿𝑿𝑿𝑿
𝑿𝑿𝑿)

Below is the truth table for XOR Gate:

A B X

0 0 0
 0 1 1

1 0 1

1 1 0

Ladder logic for XOR gate is as follows:

NOT Gate:

NOT Gate is an electrical circuit that converts signal so that the output is LOW when incoming signal is HIGH.
Mathematical notation for NOT Gate is:

𝑿=𝑿

Below is the truth table for NOT Gate:

A 𝑿
0 1
 1 0

Ladder logic for NOT gate is as follows:

Alarm System:

An Alarm system given in the problem warns us about some kind of fire danger:

2. Any 1 signal turn the warning light on

3. Any 2 signals will sound the siren
4. All 3 signals will start the water spray system.
PLC Motor:

A PLC motor controller has a start button and two stop buttons. The motor is to run if START button is
Pressed. Motor stops by pressing any STOP button stops.

Conclusion:

In this lab we have learnt how to implement different logic gates and by using such logics how we can
control different household appliances using Allen Bradley PLC.
 Lab # 04
Latch and Unlatch

Objectives:
 Understand the operation of latching and un-latching (OTL and OTU).

Lab Tasks:
Exercise:1

Implement the given logic equation using latch and unlatch.

X = AB + DC’ + B’C

Simulations:

Exercise:2

We need to start/stop the motor. When the start button is pushed we want to start the motor, and when the
stop button is pushed we want to stop the motor.

a) Implement using latch/unlatch

b) Implement without using latch/unlatch (Hint Use Feedback approach).

Exercise: 3

Design a ladder logic for bi-directional motor (Forward/ reverse). Each direction has its own button and only
one button to stop the motor. We also need to stop the motor before we change its direction.
a) Implement using latch/unlatch

b) Implement without using latch/unlatch (Hint Use Feedback approach).

Simulations:

Exercise:4

Design a ladder logic program for simple level detector both are active low logic. Motor is active high logic.

Simulations:
 Conclusion:
We learned about the operation of OTL (latching) and OTE (unlatching) in PLC programming in this lab.
We designed the ladder logic for our lab tasks using latching and unlatching, as well as without latching and
unlatching, using the feedback approach. When we assign the address that corresponds to the physical
output address for the OTL instruction and set this bit, the output device connected to the screw terminal is
powered on. When the rung condition is no longer true, the bit remains set and the corresponding output
device is powered off. To disable the output, the other inputs must be unlocked, i.e., the OTE must be
unlatched.
 LAB # 5
Introduction to TIMERS
(TIMER ON)
Objectives:
To understand the operation of Timer On and simulate the given tasks in Allen Bradley PLC.

Abstract:
Timers are very important in ladder logic programming. Timers gives the precision in time. Timer on
delay starts timing when instruction is true. Timers are used to track time when instruction are on or off.
They could also keep track on a retentive base.

Lab tasks:

Exercise#1:

Design a ladder diagram for the scenario:

Output to turn on after 10s of Input goes to logic 1.

a) Input cannot turn to logic 0 with in these 10s.

b) Input can turn to logic 0 with in these 10s.
 Exercise#2:
Lets say we have in the field an emergency stop(push button). Once the emergency stop is pressed we want
the siren to go on after 5 sec for 5 sec.
 Exercise#3:

Let’s say that we have a conveyor, siren and 1 limit switch LS-01. LS-01 is at the beginning of the
conveyor. When LS-01 is ON we want a buzzer to go on for 3 seconds (Security) and then we want to start
the conveyor. When LS-01 is cleared then we want to stop the conveyor.

Conclusion:
In this lab, we performed the given tasks by using the timer on delay. The tasks were performed
without any problem and the tasks were completed perfectly. The concept of the timer on delay was cleared.
 LAB # 6
COUNTERS
Objectives:
To understand the operation of Counters and simulate the given tasks in Allen Bradley PLC.

Abstract:
Counters are very essential in ladder logic programming. Counters are used to index, increment or
decrement values. In this lab we will implementing counters in the PLC programming.

Lab tasks:

Exercise#1:
Let us consider a system in which we have a switch to turn on a light when the switch is pressed 10
times the light should energize. We should also have a reset button.

Exercise#2:
A motor will be controlled by two switches. The Go switch will start the motor and the Stop switch
will stop it. If the Stop switch was used to stop the motor, the Go switch must be thrown twice to start the
motor. When the motor is active a light should be turned on. The Stop switch will be wired as normally
closed (Active Low).
Exercise#3:
Write a ladder logic program that does what is described below.

 When button A is pushed, a light will flash for 5 seconds.

 The flashing light will be on for 0.25 sec and off for 0.75 sec.
 If button A has been pushed 5 times the light will not flash until the system is reset.
 The system can be reset by pressing button B
 Exercise#4:

 Start the process when start is press.

 System can be stop at any time by pressing stop and remain continue working from its previous state.
 Fill each box with five balls and start conveyor 2 for 5 sec.
 Conclusion:
In this lab, we performed the given tasks by using counters and timers. The tasks were performed
without any problem and the tasks were completed perfectly. The concept of the counters and timers was
cleared.
 LAB # 7
Comparison Command
Objectives:
To understand the functions of Comparison Command in different applications and simulate
different tasks.

Abstract:
In this lab we will perform tasks related to comparison commands in PLC programming and using
these comparison commands we will perform the given tasks. Using comparison command are an input
instruction that allow much more programming possibilities. Data compare instructions compare data that
are stored in two or more words and make decisions based on the program instructions. Numeric data
comparisons that can be done are greater than (>), less than (<), equal to (=), less than or equal to (≤),
greater than and equal to (≥), not equal to (≠).

Lab tasks:

Exercise#2:
Consider a system in which we have a switch to turn on the light and fan. Light goes on when the
switch is pressed 5 times and a fan when pressed 10 times. Also, reset the switch.
 Exercise#3:
Traffic Control Using 3 Lights

From the simulation menu at the top of the screen, select the Traffic Light. Using your knowledge of timers
and comparison instruction, develop a ladder logic program which will sequence a set of green, yellow and
red light in the following.
 Exercise#4:
Traffic Control Using 6 Lights

Modify your program so that the 3 lights which represent the other traffic direction are also controlled.
Conclusion:
In this lab, we performed the given tasks by using the comparison commands. The tasks were
performed without any problem and the tasks were completed perfectly. The concept of the comparison
command was cleared.