SCHOOL OF MECHANICAL AND BUILDING SCIENCES B.

Tech Mechanical Engineering - IV semester (FFCS) Assignment on PLC Programming May 2010 Course Code : 09MEE229 Course Name : Mechatronics

1. Try to develop the PLC ladder logic program for a relay based controller that will allow three switches in a room to control a single light. 2. Draw the ladder diagram to represent (i) Two switches are normally open and both have to be closed for a motor to operate. (ii) Either of two, normally open switches have to be closed for a coil to be energized and operate an actuator? (iii) A motor is switched on by pressing a spring return bush button start switch and the motor remains on until another spring return bush button stop switch is pressed? 3. Develop the ladder logic that will turn on a light, after switch A has been closed 5 times. Push button B will reset the counters. 4. Devise a system, using a PLC that could be used with a conveyor belt which is used to move an item to work station. The presence of the item at the work station is detected by means of breaking a contact activated by a beam of light to a photosensor. There it stops for 100sec for an operation to be carried out and then starts moving. The motor for the belt is started by a normally open start switch and stopped by a normally closed switch. 5. Devise a circuit that could be used with a domestic washing machine to switch on pump to pump water for 100 sec into the machine, then switch off the pump and switch on a heater for 50sec to heat the water. The heater is then switched off and another pump is switched on for 100sec to empty the water from the machine.

6. Write a PLC ladder logic program for the following: The figure. 1 illustrates a conveyor system using two pneumatic cylinders A and B for lowering bales of hay.

Figure. 1. Cylinder Sequential control (B-A+A-B+) Conveyer 1 supplies bales of hay which need to be lowered to conveyor 2 to be transported away for storage. The sequencing of the pneumatic spring return cylinders is critical in order to complete the transfer of each bale successfully.

Note: Both cylinders must never extend together.

7.. Write the PLC ladder logic program for the electro-pneumatic sequence control (shown in Figure.2) for the following conditions. Conditions: i) Magnetic sensors I1 and I3 are initially sensed. ii) When the workpiece from conveyor belt 1 reaches to the platform of cylinder A, then sensor S1 senses it and actuates the cylinder A to extend. This operation will elevate the workpiece to the conveyer belt 2. iii) Once the extension is over, Sensor I2 will sense and actuate the cylinder B to extend this operation and pushes the workpiece to the conveyer belt 2. iv) After the extension process cylinder A should retract and then the cylinder B should retract. v) When the proximity sensor S2 senses the object the conveyer motor2 stops for 5 seconds for machining purpose. After 5 seconds, the conveyor motor2 has to start again to deliver the machined components to the next machine. vi) The process should be continuous.
Drilling Machine

I3 Cylinder B Workpiece

I4 S2

S1

Conveyer Belt 2

Conveyer Belt 1

I2

I1 Cylinder A Figure. 2. Cylinder Sequential control (A+B+A-B-) Note : I1, I2,I3 and I4 are the Magnetic sensors placed on the cylinders. S1 and S2 is the Proximity sensor.

8. Write the PLC program for the following control of a heating oven. application. The system is started with a Start button that seals in the Auto mode. This can be stopped if the Stop button is pushed. (Remember: Stop buttons are normally closed.) When the Auto goes on initially the TON timer is used to sound the horn for the first 10 seconds to warn that the oven will start, and after that the horn stops and the heating coils start. When the oven is turned off the fan continues to blow for 300s or 5 minutes after. 9. Write the PLC program for the following application. A counter is used to remove 5 out of every 10 parts from a conveyor with a pneumatic cylinder. When the part is detected both counters will increase their values by 1. When the sixth part arrives the first counter will then be done, thereby allowing the pneumatic cylinder to actuate for any part after the fifth. The second counter will continue until the eleventh part is detected and then both of the counters will be reset.

10. Write the PLC programming for the following application: Fig. 1 illustrates a tank of water which is under program control using a PLC. When the water falls below the float switch level, the tank will be stopped up automatically by the top-up valve. If the water level remains below the float switch level for more than 2 minutes, then an audible alarm will sound.

Figure: 1. Water Tank