FLOWCHART BASED DESIGN

A flowchart is ideal for a process that has sequential process steps. The
steps will be executed in a simple order that may change as the result of
some simple decisions.
FLOWCHART BASED DESIGN
 FLOWCHART BASED DESIGN
The general method for constructing flowcharts is:
1. Understand the process.
2. Determine the major actions, these are drawn as blocks.
3. Determine the sequences of operations, these are drawn with arrows.
4. When the sequence may change use decision blocks for branching.
FLOWCHART BASED DESIGN
 FLOWCHART BASED DESIGN

Each block in the flowchart will be converted to a block of ladder logic.

To do this we will use the MCR (Master Control Relay) instruction.

If the first MCR line is true then the ladder logic on the following
lines will be scanned as normal to the second MCR. If the first line is
false the lines to the next MCR block will all be forced off. If a normal
output is used inside an MCR block, it may be forced off. Therefore
latches will be used in this method.
FLOWCHART BASED DESIGN
FLOWCHART BASED DESIGN
FLOWCHART BASED DESIGN
FLOWCHART BASED DESIGN
FLOWCHART BASED DESIGN
FLOWCHART BASED DESIGN
FLOWCHART BASED DESIGN
FLOWCHART BASED DESIGN
Two ingredients, A and B,
will be mixed in the
reactor tank. The reactor
tank must be empty
(indicated by the normally
closed liquid level switch
LLS) and at a temperature
of 100°C before ingredient
A can be added. The mixer
motor must be off to avoid
liquid precipitation, and
the finished product tank
should be in a set position,
which the limit switch
detects.
FLOWCHART BASED DESIGN
Once the reactor tank reaches an
initial temperature of 100°C, the
controller will add ingredient A by
opening solenoid valve 1 (SOL1) until
100 gallons of ingredient A have
been poured into the tank. LLS1,
which is normally open, detects the
quantity of ingredient A in the tank.
This switch closes when ingredient A
reaches the proper level. At this
point, the controller will add
ingredient B by opening SOL2. LLS2
detects the quantity of ingredient B,
which should be 400 gallons. The
temperature should be at 100°C ±
10% during the Add Ingredients
step. If the temperature drops, the
PLC will turn ON the heater
automatically while the process
continues.
FLOWCHART BASED DESIGN

When the reactor tank contains both

ingredients, the controller will raise
the temperature to 300°C ± 10% and
turn ON the mixer for 20 minutes.
The PLC will control the temperature
automatically at predefined set
points during the process.

SOL3 will activate the drain valve

when the mixing is completed. This
operation will reset the process until
another finished product tank is
placed in position, and the cycle
starts again. The system should
incorporate pilot light indicators to
alert the operator to the status of
the batching process.
 FLOWCHART BASED DESIGN

SEQUENCE BITS
In general there is a preference for methods that do not use MCR
statements or latches. The flowchart used in the previous example can
be implemented without these instructions using the following method.
FLOWCHART BASED DESIGN
FLOWCHART BASED DESIGN
FLOWCHART BASED DESIGN
FLOWCHART BASED DESIGN
 FLOWCHART BASED DESIGN
Latihan
 FLOWCHART BASED DESIGN
Latihan
A machine is being designed to wrap boxes of chocolate. The boxes
arrive at the machine on a conveyor belt. The list below shows the
process steps in sequence.
1. The box arrives and is detected by an optical sensor (P), after this the
conveyor is stopped (C) and the box is clamped in place (H).
2. A wrapping mechanism (W) is turned on for 2 seconds.
3. A sticker cylinder (S) is turned on for 1 second to put consumer
labelling on the box.
4. The clamp (H) is turned off and the conveyor (C) is turned on.
5. After the box leaves the system returns to an idle state.