TILI Automation

 Develop ladder logic program for Motor ON OFF according to the logic given below, The start button is pressed to start the conveyor motor Cases move past the proximity switch and increment the counter’s accumulator value. After the count of 3, the conveyor motor stops automatically and the counter’s accumulator value is reset to 0. Restart button is used to start the process from the beginning. The conveyor motor can be stopped and started manually at any time without loss of the accumulator count. Accumulated count of the counter can be reset manually at any time by means of the count reset button. PLC Motor Logic Motor Logic Explanation Rung 0000: Start/Stop PB latched with memory B3:0/0. Rung 0001: B3:0/0 enabled to turn ON conveyor motor  (O:0/0 ). B3:0/1 is connected in series with normally closed contact to break the line when counter accumulator value reached 3. Rung 0002:  B3:0/0 and proximity sensor (I:0/2) are connected in series to input the counter presented ...

 Develop PLC Programming Examples on Industrial Automation according to the logic given below, A Saw, Fan and oil pump all go ON when a start button is pressed. If the saw has operated less than 20s, the oil pump should go off when the saw is turned off and the fan is to run for an additional 5s after the shutdown of the saw. If the saw has operated for more than 20s, the fan should remain on until reset by a separate fan reset button and the oil pump should remain on for an additional 10 s after the saw is turned off. Write a program that will implement this process. PLC Programming Examples Program Description: Rung 0000: Start/Emergency Stop PB latched with memory B3:0/0. Rung 0001: B3:0/0 enabled to turn on Saw (O: 0/0), Fan (O: 0/1 ) and Oil pump (O:0/2). Normally closed contact of Stop switch is in series Saw output to turn off. Fan reset switch and Timer T4:0 is connected to turn off Fan when condition meets. Timer T4:2 done a bit and memory bit is to turn off the oil pump. ...

PLC Programming Limit Switch Develop PLC Programming Example using Limit Switch according to the logic given below, The system is started by an operator each shift, and the item to be sorted are then fed onto the production line conveyor. Once the start is pressed conveyer should ON, the items proceed, operating limit switch 1, which counts all the items. Limit switch 2 counts only the larger items. Limit switch 3 counts only the larger items. As limit switch 2 is operated, a pneumatic ram 1 is activated and thus stores all the larger items in the bigger box. As limit switch 3 is operated, a pneumatic ram 1 is activated and thus stores all the larger items in the smaller box. At the end of 2 items, next bigger box output and smaller box output turns ON to shift new boxes. The counter automatically resets when the preset value meets the accumulator value. When operator press end of work, It waits for 10s to turn off conveyor motor in between any items crosses limit switch, it should...

 This is a PLC Program to count running hours of any equipment using bit instructions, math instructions, and counters. PLC Running Hours In industry, it is sometime necessary to count running hours of any equipment (pumps, compressors, motors) to maintain its efficiency, equipment life as well as periodic maintenance. By using PLC instruction we can prepare a PLC program to count the running hours of any equipment. PLC Programming Here is the PLC program to count the running hours of any equipment. Network 1: This network adds the 1 second at every 1-second pulse when there is running feedback of equipment and there is no reset bit. Network 2: This is the network that converts seconds into the hour. Network 3: In this network, we are getting the remaining second by mod instructions and then convert it into minutes. Network 4:  This network converts minute into seconds. Network 5: These two networks are for reset logic. When there are 1000 hours in the count it will add count ...

 Explain PLC programming for the Automated Guided Vehicle (AGV) in the manufacturing plant. Here we are discussing some part of the working in AGV as an example program in PLC. Here we are using the ultrasonic sensor concept for object detection in the way of AGV. The automated guided vehicle work as line follower robot. If there is an object in front of the AGV it will stop running. For this, we will use the ultrasonic sensor for object detection. When the object is detected, the ultrasonic sensor will give the command to the PLC. The ultrasonic sensor generates the sound on some frequency which travels through air and if objects in its path it will bounce from the object and back to sensor. From the equation, we can count the distance. For example – We can calculate the distance as per the equation. Consider here sound wave takes 294micro second for traveling (total time is taken from the sensor to object and object to the sensor). So here we can calculate the distance. Time = Di...

Develop PLC Programming Batch Process ladder logic program according to the logic given below, Ingredient A is sent to the tank first by energizing solenoid 1. The flow meter gives one pulse for every gallon of flow. Solenoid Valve will be open until 200 gal has poured in. After ingredient A is in the tank, 200 gal of ingredient B should be added. The process of adding follows the same procedure as ingredient A. Once step 2 is done, the mixer motor starts and runs for 10s. After mixing is complete, solenoid 3 should open, let the mixed batch goes to the finished tank. When the tank is empty, the low-level sensor turns ON to open solenoid 3 to close and restarts the process again.  PLC Programming Batch Process Program Description: Rung 0000: Start/Stop PB latched with memory B3:0/0. Rung 0001: B3:0/0 enabled to turn on solenoid A (O: 0/0). Until B3:0/2 turns ON. Rung 0002 & 0003: Flowmeter (I:0/2) is connected to one shot to give one pulse when flow meter reads 1 gallon of ingr...

Develop ladder logic program for PLC-based Drink Dispenser System according to the logic given below, Press the power button to activate the power supply as shown in the figure. Put manually glass (or a cup) on conveyor to hold up drink A/B/C as shown in the below figure. Press a one-button from A/B/C whatever you choose on the available types of drinks (It is toggle type switch). Press the start button from the local panel. The glass (or a cup) moves from limit switch 2 to 4 and stops the conveyor when glass reaches the appropriate limit switch, which we select from the A/B/C toggle switch. Glass (or a cup)  fill by drink A/B/C for 15 sec.(as per glass size) and conveyor again start-up to glass not reach limit switch -5. PLC Dispenser System  INPUTS: I:0.0 – POWER ON PB I:0.1 – POWER OFF PB I:0.2 – START PB I:0.3 – STOP PB I:0.4 – LIMIT SWITCH, L1 I:0.5 – LIMIT SWITCH, L2 I:0.6 – LIMIT SWITCH, L3 I:0.7 – LIMIT SWITCH, L4 I: 0.8 – LIMIT SWITCH, L5 I:0.9 – SWITCH A I:0.10 – SWI...

 Design a PLC program to control the liquid level in a tank. A level transmitter is used to measure the tank level into a standard current signal from 4 to 20mA as illustrated in the below process diagram. Tank Level Control in PLC PLC Program Logic The agitator motor is to be started and stopped by a pushbutton station. The solenoid valves are to be open (Energized) when the agitator is running. Pump N0.1 starts at the 75% liquid level and stops at the 25% level. The pump will run only if the agitator is running. On a high-level alarm (Tank 90%), an alarm light will come ON and stay on even if the tank level drops. An operator must press the reset button to turn off the light. On the high-level alarm, both the solenoid valve will also close (de-energize). A low-level alarm light shall be provided (Tank 10%), similar to the high level, and reset using the same pushbutton. Scaling Tabular Column: PLC Programming for Tank Level Control PLC Program Description Rung 0000: Start/Stop PB...

 Grounding electronic equipment for personal safety and clearing of faults is no different than that of any other equipment. Safe grounding requires fast opening of circuit breakers or fuses and minimization of voltage differences between exposed metal surfaces on all of the involved electrical system and equipment, to levels that are safe for people. What makes electronic systems different is the sensitivity of their circuit components to relatively small transient currents and voltages. It is also inherent in the nature of solid state devices to be very fast, so they are affected by equally “fast” electrical disturbances. Even lightning is a slow transient compared to the response of almost any electronic device. Typical threats to proper operation of electronic devices and systems include: 1. Lightning Direct strikes, but the effects also include overhead cloud-to-cloud, and nearby strikes causing induced voltages 2. Switching Transients Switching transients from power network o...

 A formal definition of a ground loop that is very general is provided in IEEE Std. 100-1991, IEEE Dictionary as follows: . . . a ground loop is “formed when two or more points in an electrical system that are nominally at ground potential are connected by a conducting path such that either or both points are not at the same potential.” While this is a good general purpose definition, it is not sufficiently specific for use when dealing with signal level circuits and grounding connections. Therefore, a more specific and useful definition as provided in this document is as follows: Ground Loop (unwanted) Any conductive path involving “ground” via a grounding or grounded conductor or the earth itself, through which any part or all of the desired signal process current is passed, so that it may be algebraically added to any unwanted current such as “noise” that may also be flowing in the shared ground path. Ground Loop (desired) Any number of paralleled conductors and connections invo...

 Develop a PLC-based ladder logic program for automatic packaging system according to the logic given below, Start and stop PB is used to start and stop the whole process Photosensor is used to detect product. Once the count reaching 10, the robot arm takes responsible for packing. Packing complete sensor turns on to restart the process Stop PB is pressed any time to stop all processes. PLC Packaging System PLC Packaging Programming Program Description: Rung 0000: Start/Stop Pushbutton (PB) latched with memory B3:0/0. Rung 0001: B3:0/0 enabled to turn on Conveyer motor (O: 0/0). Rung 0002: Photo-sensor (I:0/1) is connected to one shot to give one pulse when a product crossing photo-sensor. The counter is used to count the number of the product. Robotic arm for packing (O:0/1) is connected in the normally closed contact to give interlocking with conveyor motor. Rung 0003: Counter done bit turns robotic arm for packing (O: 0/1) to turn ON and conveyor motor to stop. Rung 0004: Packin...

 Write the PLC program to control multiple pumps using programmable logic controllers. We have two input pumps used to fill a tank. Make sure pumps operate in an equal amount of time over their lifetime. Multiple Pumps Control using PLC Program Logic: Develop ladder logic program according to the logic given below, The start/stop push button is provided for control of the two input pump motors P1 and P2. The Start/Stop pushbutton station is operated to control pump P1. When the tank is full drain pump motor P3 is started automatically and runs until the low-level sensor is actuated. After 3 fillings of the tank by pump P1 control automatically shifts to pump P2. The operation of the start/stop pushbutton now controls pump P2. After 3 fillings of the tank by pump P2, the sequence is repeated. PLC Program: Program Description: Rung 0000: Start/Stop PB latched with memory B3:0/0. Rung 0001: B3:0/0 enabled to turn on B3:0/1 which is to turn ON PUMP P1 (O:0/0) when low-level sensor(I:0/...

 Write the PLC programming for a continues box filling operation that requires boxes moving on a conveyor to be automatically positioned and filled. Automatic Box Filling System Develop ladder logic program according to the logic given below, Energize the RUN status light when the process is operating. Energize the STANDBY status light when the process is stopped. Stop the conveyor and energize the standby light when the right edge of the box is first sensed by the photo sensor. With the box in position and the conveyor stopped, after 3 seconds open the solenoid valve and allow the box to fill. The filling should stop when the level sensor goes true. Energize the FULL light when the box is full. The FULL light should remain energized until the box is moved clear of the photo sensor. Box Filling using PLC Logic Logic Description: Rung 0000: Start/Stop PB latched with memory B3:0/0. Rung 0001: B3:0/0 enabled to turn on Run status light (O:0/0) and Conveyer motor (O:0/1). The Photosen...

 Example 1 To develop a ladder diagram for the ON/OFF temperature controller for the continuous process of heating of mixture. Sequence: On button to start the process when motor start and V1 is open. Then check the level, is it high level is reached or not. If a high level is reached turn ON the stirrer & heater at a time. After mixing & heating turn OFF the stirrer & heater. Finally, release this mixture through valve V2. PLC Programs Temperature Control using Thermostat PLC based Tank Heating Control Automatic Mixing Control in a Tank Example 2 Develop a ladder program for wood saw cutter. A wood saw cutter (W), a fan (F) and a lubrication pump (P) turns on when a START push button is pushed. Following is the stopping sequence: STOP push-button stops the saw only before fan stops it should run for an additional 5 sec to blow the chips away and also the tube pump is to run for 8 sec. Additionally, before it stops. if the saw has run more than 1 min, the fan should sta...