Automation Production Systems and Computer

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Automation Production Systems and Computer Integrated Manufacturing 4th Edition Groover Solu

PLCs-4e-A&S 06-04, 06-07, 06-12-2013

Chapter 9
DISCRETE CONTROL AND PROGRAMMABLE LOGIC CONTROLLERS
REVIEW QUESTIONS
9.1 Briefly define the two categories of discrete process control?
Answer: Discrete process control can be divided into two categories: (1) logic control,
which is concerned with event-driven changes in the system; and (2) sequence control,
which is concerned with time-driven changes in the system.
9.2 What is an AND gate? How does it operate on two binary inputs?
Answer: An AND gate outputs a value of 1 if all of the inputs are 1, and 0 otherwise.
9.3 What is an OR gate? How does it operate on two binary inputs?
Answer: An OR gate outputs a value of 1 if either of the inputs has a value of 1, and 0
otherwise.
9.4 What is Boolean algebra? What was its original purpose?
Answer: Boolean algebra is a special form of algebra based on the logic elements (AND,
OR, and NOT) that was developed around 1847 by George Boole. Its original purpose was
to provide a symbolic means of testing whether complex statements of logic were TRUE
or FALSE.
9.5 What is the difference between a delay-off timer and a delay-on timer?
Answer: A delay-off timer switches power on immediately in response to a start signal,
and then switches power off after a specified time delay, whereas a delay-on timer waits a
specified length of time before switching power on when it receives a start signal.
9.6 What is the difference between an up counter and a down counter?
Answer: An up counter starts at zero and increments its contents (the count total) by one in
response to each pulse. When a preset value has been reached, the up counter can be reset
to zero. A down counter starts with a preset value and decrements the total by one for each
pulse received.
9.7 What is a ladder logic diagram?
Answer: A ladder logic diagram shows the various logic components along horizontal
lines or rungs connected on either end to two vertical rails. The diagram has the general
configuration of a ladder, hence its name. The components are contacts (representing
logical inputs) and loads, also known as coils (representing outputs).
9.8 The two types of components in a ladder logic diagram are contacts and coils. Give two
examples of each type.
Answer: Contacts include switches and relay contacts, and coils include motors, lamps,
and alarms.
9.9 What is a programmable logic controller?
Answer: A programmable logic controller is a microcomputer-based controller that uses
stored instructions in programmable memory to implement logic, sequencing, timing,

9-1
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counting, and arithmetic functions through digital or analog input/output (I/O) modules, for
controlling machines and processes.
9.10 What are the advantages of using a PLC rather than conventional relays, timers, counters,
and other hard-wired control components?
Answer: The advantages listed in the text are (1) programming the PLC is easier than
wiring the relay control panel; (2) the PLC can be reprogrammed, whereas conventional
controls must be rewired and are often scrapped instead; (3) PLCs take less floor space
than relay control panels; (4) reliability is greater, and maintenance is easier; (5) the PLC
can be connected to computer systems more easily than relays; and (6) PLCs can perform a
greater variety of control functions than relay controls can.
9.11 What are the four basic components of a PLC?
Answer: The four basic components of a PLC are the following: (1) processor, (2) memory
unit, (3) power supply, and (4) I/O module. In addition, a programming device is required
to enter the control program to the PLC. In most cases, this can be disconnected from the
PLC when not being used.
9.12 The typical operating cycle of the PLC, called a scan, consists of three parts: (1) input
scan, (2) program scan, and (3) output scan. Briefly describe what is accomplished in each
part.
Answer: During the input scan, the inputs to the PLC are read by the processor and the
status of each input is stored in memory. Next, the control program is executed during the
program scan. The input values stored in memory are used in the control logic calculations
to determine the values of the outputs. Finally, during the output scan, the outputs are
updated to agree with the calculated values.
9.13 Name the five PLC programming methods identified in the International Standard for
Programmable Controllers (IEC 61131–3).
Answer: The standard specifies three graphical languages and two text-based languages
for programming PLCs, respectively: (1) ladder logic diagrams, (2) function block
diagrams, (3) sequential functions charts, (4) instruction list, and (5) structured text.
9.14 What are the reasons and factors that explain why personal computers are being used with
greater and greater frequency for industrial control applications?
Answer: Some of the reasons given in the text are the following: (1) The technological
evolution of PLCs has not kept pace with the development of PCs. (2) New generations of
PCs are introduced with much greater frequency than PLCs. (3) There is much more
proprietary software and architecture in PLCs than in PCs, making it difficult to mix and
match components from different vendors. (4) PCs are now available in more-sturdy
enclosures for the dirty and noisy plant environment. (5) PCs can be equipped with
membrane-type keyboards for protection against factory moisture, oil, and dirt. (6) PCs can
be ordered with I/O cards and related hardware to provide the necessary devices to connect
to the plant’s equipment and processes. (7) Operating systems designed to implement real-
time control applications can be installed in addition to traditional office software.
9.15 Name the two basic approaches used in PC-based control systems.
Answer: The two approaches are soft logic and hard real-time control. In the soft logic
configuration, the PC’s operating system is Windows, and control algorithms are installed

9-2
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as high-priority programs under the operating system. However, it is possible to interrupt

the control tasks in order to service certain system functions in Windows, such as network
communications and disk access. When this happens, the control function is delayed, with
possible negative consequences to the process. By contrast, in a hard real-time control
system, the PC’s operating system is the real-time operating system, and the control
software takes priority over all other software. Windows tasks are executed at a lower
priority under the real-time operating system. Windows cannot interrupt the execution of
the real-time controller. If Windows locks up, it does not affect the controller operation.
Also, the real-time operating system resides in the PC’s active memory, so a failure of the
hard disk has no effect in a hard real-time control system.
9.16 Modern industrial control applications have evolved to include requirements in addition to
logic and sequence control. What are these additional requirements?
Answer: The additional requirements of modern industrial control applications include the
following: (1) analog control to cope with continuous process variables like temperature,
(2) motion and servomotor control, (3) arithmetic functions to permit application of
complex control algorithms, (4) matrix functions, (5) data processing and reporting, and
(6) network connectivity and enterprise data integration.
9.17 What is a programmable automation controller?
Answer: A programmable automation controller (PAC) is an industrial process controller
designed to interface with the sensors and actuators whose signals are typically binary, like
a conventional PLC, but it also has capabilities usually associated with personal computer
applications, such as simulated analog control, data processing, advanced mathematical
functions, network connectivity, and enterprise data integration. In effect, a PAC combines
the input/output and discrete control capabilities of a PLC with the advanced
computational, data processing, and enterprise integration capabilities of a PC.
PROBLEMS
Answers to problems labeled (A) are listed in the Appendix at the back of the book.
9.1 Construct the truth table for the robot interlock system in Example 9.1.
Solution: Truth table, given the symbols defined in Example 9.1.
X1 X2 X3 Y
0 0 0 0
1 0 0 0
0 1 0 0
1 1 0 0
0 0 1 0
1 0 1 0
0 1 1 0
1 1 1 1
9.2 Construct the ladder logic diagram for the robot interlock system in Example 9.1.
Solution: Ladder logic diagram, given the symbols defined in Example 9.1.
⏐ X1 X2 X3 Y ⏐
⏐⎯⎯⏐⏐⎯⎯⏐⏐⎯⎯⏐⏐⎯⎯( )⎯⎯⏐
⏐ ⏐

9-3
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9.3 (A) Write the Boolean logic expressions for the pushbutton switch of Example 9.2 using the
following symbols: X1 = START, X2 = STOP, P = POWER-TO-MOTOR, and M =
MOTOR. Hint: See Figure 9.6(b).
Solution: Given X1 = start, X2 = stop, P = power-to-motor, and M = motor,
Boolean logic expressions: P = (X1 + P) ⋅ X2 and M = P
9.4 In the circuit of Figure 9.1, suppose a photodetector were used to determine whether the
lamp worked. If the lamp does not light when both switches are closed, the photodetector
causes a buzzer to sound. Construct the truth table for this system.
Solution: Using the following symbols: X1 = first switch, X2 = second switch, Y = lamp (Y
= 1 when on), X3 = photodetector (X3 = 0 when light is detected, X3 = 1 when no light is
detected), and B = buzzer (B = 1 means buzzer is sounding), the truth table is as follows:
Line X1 X2 Y X3 B
1 0 0 0 1 0
2 0 1 0 1 0
3 1 0 0 1 0
4 1 1 1 0 0
5 1 1 0 1 1
Comment: In line 5, Y = 0 indicates that the lamp is not lighting, thus photodetector X3 = 1.
Because X1 and X2 are also closed, the buzzer is energized to sound.
9.5 Construct the ladder logic diagram for the preceding problem.
Solution: Using the symbols and their values from the preceding problem, the ladder logic
diagram is as follows:
⏐ X1 X2 Y ⏐
⏐⎯⎯⏐⏐⎯⎯⏐⏐⎯⎯⎯⎯⎯( )⎯⎯⏐
⏐ ⏐
⏐ X1 X2 X3 B ⏐
⏐⎯⎯⏐⏐⎯⎯⏐⏐⎯⎯⏐⏐⎯⎯( )⎯⎯⏐
⏐ ⏐
9.6 In the circuit of Figure 9.2, suppose a photodetector were used to determine whether the
lamp worked. If the lamp does not light when either X1 or X2 switch is closed, the
photodetector causes a buzzer to sound. Construct the truth table for this system.
Solution: Using the following symbols: X1 = first switch, X2 = second switch, Y = lamp (Y
= 1 when on), X3 = photodetector (X3 = 0 when light is detected, X3 = 1 when no light is
detected), and B = buzzer (B = 1 means buzzer is sounding), the truth table is as follows:
Line X1 X2 Y X3 B
1 0 0 0 1 0
2 0 1 1 0 0
3 1 0 1 0 0
4 1 1 1 0 0
5 0 0 0 0 0
6 0 1 0 1 1
7 1 0 0 1 1
8 1 1 0 1 1

9-4
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 PLCs-4e-A&S 06-04, 06-07, 06-12-2013

Comment: In lines 6, 7, and 8, Y = 0 indicates that the lamp is not lighting, thus
photodetector X3 = 1. Because either X1 or X2 is also closed, or both X1 and X2 are closed,
the buzzer is energized to sound.
9.7 Construct the ladder logic diagram for the preceding problem.
Solution: Using the symbols and their values from the preceding problem, the ladder logic
diagram is as follows:
⏐ X1 Y ⏐
⏐⎯⎯⏐⏐⎯⎯⎯⎯⎯⎯⎯( )⎯⎯⏐
⏐ X2 ⏐ ⏐
⏐⎯⎯⏐⏐⎯⎯⏐ ⏐
⏐ X1 X3 B ⏐
⏐⎯⎯⏐⏐⎯⎯⎯⎯⏐⏐⎯⎯( )⎯⎯⏐
⏐ X2 ⏐ ⏐
⏐⎯⎯⏐⏐⎯⎯⏐ ⏐
⏐ ⏐
9.8 Construct the ladder logic diagrams for (a) the NAND gate and (b) the NOR gate.
Solution: Ladder logic diagrams, using the following symbols: X1 = first switch, X2 =
second switch, Y1 = intermediate output load, and Y = output load of interest.
(a) NAND
⏐ X1 X2 Y1 ⏐
⏐⎯⎯⏐⏐⎯⎯⏐⏐⎯⎯⎯( )⎯⎯⏐
⏐ Y1 Y ⏐
⏐⎯⎯⏐⁄⏐⎯⎯⎯⎯⎯⎯( )⎯⎯ ⏐
⏐ ⏐
(b) NOR
⏐ X1 Y1 ⏐
⏐⎯⎯⏐⏐⎯⎯⎯⎯⎯( )⎯⎯⏐
⏐ X2 ⏐ ⏐
⏐⎯⎯⏐⏐⎯⎯⏐ ⏐
⏐ Y1 Y ⏐
⏐⎯⎯⏐⁄⏐⎯⎯⎯⎯⎯( )⎯⎯⏐
⏐ ⏐
9.9 Draw the ladder logic diagram for the Boolean logic equation: Y = (X1 + X2)⋅X3.
Solution: Ladder logic diagram for Y = (X1 + X2)⋅X3.
⏐ X1 X3 Y ⏐
⏐⎯⎯⏐⏐⎯⎯⎯⎯⏐⏐⎯⎯( )⎯⎯⏐
⏐ X2 ⏐ ⏐
⏐⎯⎯⏐⏐⎯⎯⏐ ⏐
⏐ ⏐
9.10 Draw the ladder logic diagram for the Boolean logic equation: Y = (X1 + X2)⋅(X3 + X4).
Solution: Ladder logic diagram for Y = (X1 + X2)⋅(X3 + X4).
⏐ X1 X3 Y ⏐

9-5
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⏐⎯⎯⏐⏐⎯⎯⎯⎯⏐⏐⎯⎯⎯( )⎯⎯⏐
⏐ X2 ⏐ X4 ⏐ ⏐
⏐⎯⎯⏐⏐⎯⎯⏐ ⎯⏐⏐⎯⏐ ⏐
⏐ ⏐
9.11 Draw the ladder logic diagrams for the Boolean logic equation: Y = (X1⋅X2) + X3.
Solution: Ladder logic diagram for Y = (X1⋅X2) + X3.
⏐ X1 X2 Y ⏐
⏐⎯⎯⏐⏐⎯⎯⎯⏐⏐⎯⎯⎯( )⎯⎯⏐
⏐ X3 ⏐ ⏐
⏐⎯⎯⎯⎯⏐⏐⎯⎯⎯⏐ ⏐
⏐ ⏐
9.12 (A) Write the language statements for Problem 9.9 using the instruction set in Table 9.10.
Solution: STR X1
OR X2
AND X3
OUT Y
9.13 Write the language statements for Problem 9.10 using the instruction set in Table 9.10.
Solution: STR X1
OR X2
AND X3
OR X4
OUT Y
9.14 Write the language statements for Problem 9.11 using the instruction set in Table 9.10.
Solution: STR X1
AND X2
OR X3
OUT Y
9.15 Write the low level language statements for the robot interlock system in Example 9.1 using
the instruction set in Table 9.10.
Solution: STR X1
AND X2
AND X3
OUT Y
9.16 Write the low level language statements for the lamp and photodetector system in Problem
9.4 using the instruction set in Table 9.10.
Solution: STR X1
AND X2
OUT Y
STR X1
AND X2
AND X3
OUT B

9-6
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9.17 An industrial furnace is controlled as follows: The contacts of a bimetallic strip inside the
furnace close if the temperature falls below the set point and open when the temperature is
above the set point. The contacts regulate a control relay which turns on and off the heating
elements of the furnace. If the door to the furnace is open, the heating elements are turned off
until the door is closed. Let X1 = contacts of bimetallic strip, X2 = door interlock, C1 = relay
contacts, and Y1 = heating elements. Construct the ladder logic diagram for the system.
Solution: Let X1 = closed if temperature falls below set point, X2 = closed if door is closed,
C1 = relay contacts, and Y1 = heating elements on. Ladder logic diagram:
⏐ X1 X2 C1 ⏐
⏐⎯⎯⏐⏐⎯⎯⏐⏐⎯⎯⎯( )⎯⎯⏐
⏐ C1 Y1 ⏐
⏐⎯⎯⏐⏐⎯⎯⎯⎯⎯⎯( )⎯⎯⏐
⏐ ⏐
9.18 (A) For the previous problem, write the low level language statements for the system using
the PLC instruction set in Table 9.10.
Solution: Let X1 = closed if temperature falls below set point, X2 = closed if door is closed,
C1 = relay contacts, and Y1 = heating elements on.
Low level language:
STR X1
AND X2
OUT C1
STR C1
OUT Y1
9.19 In the manual operation of a sheet metal stamping press, a two button safety interlock system
is used to prevent the operator from inadvertently actuating the press while his hand is in the
die. Both buttons must be depressed to actuate the stamping cycle. In this system, one press
button is located on one side of the press while the other button is located on the opposite
side. During the work cycle the operator inserts the part into the die and depresses both
pushbuttons, using both hands. (a) Write the truth table for this interlock system. (b) Write
the Boolean logic expression for the system. (c) Construct the ladder logic diagram for the
system.
Solution: Let X1 = button one, X2 = button 2, and Y = safety interlock
(a) Truth table X1 X2 Y
0 0 0
0 1 0
1 0 0
1 1 1
(b) Boolean logic expression: Y = X1⋅X2
(c) Ladder logic diagram:
⏐ X1 X2 Y ⏐
⏐⎯⎯⏐⏐⎯⎯⏐⏐⎯⎯⎯( )⎯⎯⏐
⏐ ⏐

9-7
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9.20 An emergency stop system is to be designed for a certain automatic production machine. A
single "start" button is used to turn on the power to the machine at the beginning of the day.
In addition, there are two "stop" buttons located at two locations on the machine, either of
which can be pressed to immediately turn off power to the machine. Let X1 = start button
(normally open), X2 = stop button 1 (normally closed), X3 = stop button 2 (normally
closed), and Y = power-to-machine. (a) Construct the truth table for this system. (b) Write
the Boolean logic expression for the system. (c) Construct the ladder logic diagram for the
system.
Solution:
(a) Truth table: X1 X2 X3 Y
0 1 1 0
1 1 1 1
0 1 0 0
0 0 1 0
1 1 0 0
1 0 1 0
0 0 0 0
1 0 0 0

(b) Boolean logic expression: Y = (X1 + Y) ⋅ (X2 + X3)

(c) Ladder logic diagram:
⏐ X1 X2 X3 Y ⏐
⏐⎯⎯⏐⏐⎯⎯⎯⎯⏐⁄⏐⎯⏐⁄⏐⎯⎯( )⎯⎯⏐
⏐ Y ⏐ ⏐
⏐⎯⎯⏐⏐⎯⎯⏐ ⏐
9.21 An industrial robot performs a machine loading and unloading operation. A PLC is used as
the cell controller. The cell operates as follows: (1) a human worker places a part into a nest,
(2) the robot reaches over and picks up the part and places it into an induction heating coil,
(3) a time of 10 sec is allowed for the heating operation, and (4) the robot reaches into the
coil, retrieves the part, and places it on an outgoing conveyor. A limit switch X1 (normally
open) is used to indicate that the part is in the nest in step (1). This energizes output contact
Y1 to signal the robot to execute step (2) of the work cycle (this is an output contact for the
PLC, but an input interlock signal for the robot controller). A photocell X2 is used to indicate
that the part has been placed into the induction heating coil C1. Timer T1 is used to provide
the 10-sec heating cycle in step (3), at the end of which, output contact Y2 is used to signal
the robot to execute step (4). Construct the ladder logic diagram for the system.
Solution: (a) Ladder logic diagram:
⏐ X1 Y1 ⏐
⏐⎯⎯⏐⏐⎯⎯⎯⎯⎯⎯( )⎯⎯⏐
⏐ X2 C1 ⏐
⏐⎯⎯⏐⏐⎯⎯⎯⎯⎯⎯( )⎯⎯⏐
⏐ X2 T1 ⏐
⏐⎯⎯⏐⏐⎯⎯⎯⎯⎯⎯[10 s]⎯⏐
⏐ T1 C1 ⏐
⏐⎯⎯⏐⁄⏐⎯⎯⎯⎯⎯⎯( )⎯⎯⏐

9-8
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 PLCs-4e-A&S 06-04, 06-07, 06-12-2013

⏐ T1 Y2 ⏐
⏐⎯⎯⏐⏐⎯⎯⎯⎯⎯⎯( )⎯⎯⏐
⏐ ⏐
9.22 For the previous problem, write the low level language statements for the system using the
PLC instruction set in Table 9.10.
Solution: Low level language statements:
STR X1
OUT Y1
STR X2
OUT C1
STR X2
OUT TMR T1
STR NOT T1
OUT C1
STR T1
OUT Y2
9.23 Write the low level language statements for the fluid filling operation in Example 9.6 using
the instruction set in Table 9.10. Hint: See Figure 9.5.
Solution: STR X1
OR C1
AND NOT FS
OUT C1
STR C1
OUT S1
STR NOT FS
OUT S1
STR FS
OUT T1 120 (120 specifies timer delay in sec)
STR T1
OUT C2
STR C2
OUT T2 90 (90 specifies timer delay in sec)
STR C2
OR S2
AND NOT T2
OUT S2

9.24 In the fluid filling operation of Example 9.6, suppose a sensor (e.g., a submerged float
switch) is used to determine whether the contents of the tank have been evacuated, rather
than rely on timer T2 to empty the tank. Construct the ladder logic diagram for this revised
system.
Solution: (a) Ladder logic diagram. Assume FS2 (new float switch) is open when tank is
empty. FS1 is the tank full float switch.
⏐ X1 FS1 C1 ⏐
⏐⎯⎯⏐⏐⎯⎯⎯⎯⏐⁄⏐⎯⎯⎯( )⎯⎯⏐

9-9
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the publisher prior to any prohibited reproduction, storage in a retrieval system, or transmission in any form or by any means, electronic, mechanical, photocopying,
recording, or likewise. For information regarding permission(s), write to: Rights and Permissions Department, Pearson Education, Inc., Upper Saddle River, NJ 07458
Automation Production Systems and Computer Integrated Manufacturing 4th Edition Groover Solu

PLCs-4e-A&S 06-04, 06-07, 06-12-2013

⏐ C1 ⏐ ⏐
⏐⎯⎯⏐⏐⎯⎯⏐ ⏐
⏐ C1 S1 ⏐
⏐⎯⎯⏐⏐⎯⎯⎯⎯⎯⎯⎯⎯( )⎯⎯⏐
⏐ FS1 S1 ⏐
⏐⎯⎯⏐⁄⏐⎯⎯⎯⎯⎯⎯⎯( )⎯⎯⎯⏐
⏐ FS1 T1 ⏐
⏐⎯⎯⏐⏐⎯⎯⎯⎯⎯⎯⎯[120s]⎯⎯⏐
⏐ T1 C2 ⏐
⏐⎯⎯⏐⏐⎯⎯⎯⎯⎯⎯⎯⎯( )⎯⎯⏐
⏐ C2 FS2 S2 ⏐
⏐⎯⎯⏐⏐⎯⎯⎯⎯⏐⁄⏐⎯⎯⎯( )⎯⎯⏐
⏐ S2 ⏐ ⏐
⏐⎯⎯⏐⏐⎯⎯⏐ ⏐
9.25 For the previous problem, write the low level language statements for the system using the
PLC instruction set in Table 9.10.
Solution: Low level language statements:
STR X1
OR C1
AND NOT FS1
OUT C1
STR C1
OUT S1
STR NOT FS1
OUT S1
STR FS1
OUT T1 (120 s)
STR T1
OUT C2
STR C2
OR S2
AND NOT FS2
OUT S2

9-10
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Visit
recording, orTestBankBell.com to get write
likewise. For information regarding permission(s), complete
to: Rights andfor allDepartment,
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