Variables for Lab 1,2 and 3
LAB1
Configuration PLC
I utilized a PLC setup with 140
CPU 434 12A/U 03.20 to complete the aforementioned method. Figure 1 displays
the arrangement.
Since I have two outputs and four
inputs in my simulation, DDM390 00 fits my demands. The fact that these inputs
are digital is crucial to understand. Additionally, I used CPS 211 00 as the
power source.
Figure1: Configuration PLC
Inventory of Function Blocks and Used Variables, Together with
Their Types
The variables that are used are
listed in Figure 1.2. BOOLEAN type variables are all that I used in the
application. EBOOLEAN-type program sections are used.
Algorithm
Initialization:
Set initial conditions, reset any
memory bits.
Define variables for inputs (START
button, STOP button, EMERGENCY button, FUSE) and outputs (Alarm, Contactor).
Figure2: PLC components
Main Program:
Step 1 (Alarm):
If the START button is pressed and
the EMERGENCY button is not pressed:
Turn ON the Alarm output.
Set a timer for 10 seconds.
If the timer is done (10 seconds
passed):
Turn OFF the Alarm output.
Move to the next step.
Step 2 (Delay):
If the START button is still
pressed and the EMERGENCY button is not pressed:
Set a timer for the desired delay
(if any).
If the timer is done:
Move to the next step.
Step 3 (Contactor/Motor Start):
If the START button is still
pressed and the EMERGENCY button is not pressed:
Turn ON the Contactor/Motor
output.
Step 4 (STOP Button):
If the STOP button is pressed:
Turn OFF the Contactor/Motor
output.
Step 5 (EMERGENCY Button):
If the EMERGENCY button is
pressed:
Turn OFF the Alarm output.
Turn OFF the Contactor/Motor
output.
Reset all timers.
Go back to Step 1.
Step 6 (FUSE):
If the FUSE input is active
(similar to EMERGENCY):
Turn OFF the Alarm output.
Turn OFF the Contactor/Motor
output.
Reset all timers.
Go back to Step 1.
LAB1 LD
LAB1 FBD
LAB1 ST LAB1 IL
LAB2
Configuration PLC
I have two digital inputs and one
output in this software. I thus utilized the PLC configuration 140 CPU 434
12A/U 03.20. The power and input/output combinations are chosen in accordance
with Figure 3.
Figure3: Configuration PLC
Algorithm
Figure4: PLC Components
1. Understand the Motor Direction:
Imagine there are two special
buttons called "x0" and "x1" that tell us about the motor
direction. We want to check if both x0 and x1 are OFF (LOW) or both are ON
(HIGH). I created two special signs, "DoubleDark" and "DoubleLight
to remember these conditions.
2. Detect Motor Direction:
If both x0 and x1 are OFF (LOW),
set " DoubleDark " to remember it's one way.
If both x0 and x1 are ON (HIGH),
set " DoubleLight " to remember it's the other way.
The next time we check, we will
know the motor's direction based on the remembered conditions.
3. Show Motor Direction with Lamp:
Imagine there's a lamp that shows
if the motor is turning right or left.
If " DoubleDark " is
remembered (meaning the motor is turning right), make the lamp blink.
If " DoubleLight " is
remembered (meaning the motor is turning left), keep the lamp constantly ON.
Putting it Together:
Check x0 and x1 to see their
values.
If both are OFF, set "DoubleDark."
If both are ON, set " DoubleLight "
If " DoubleDark " is
set, make the lamp blink (motor turning right). If " DoubleLight " is
set, keep the lamp ON (motor turning left).
Repeat:
Keep checking x0 and x1 to see if
the motor's direction changes.
If it changes, update " DoubleDark
" or " DoubleLight " accordingly.
Adjust the lamp based on the
updated condition.
LAB2 LD
LAB2 FBD
LAB2 ST
LAB2 IL
LAB3
140 CPU 434 12A/U 03.20 is what I
chose. I have two digital inputs (J1, J2) and one output (LAMP) in this
application. As a result, Figure 2.1's input/output and power configurations
are chosen. I am able to have 8 inputs and 4 outputs in this arrangement.
Figure 5 displays the arrangement.
Algorithm
Figure6: PLC Algorithm
Initialize Variables:
Set counters for J1 and J2 to
zero.
Create a variable to store the
difference between J1 and J2 (diff).
Main Loop:
Enter a continuous loop to repeat
the process.
Counting Pulses:
Increment counters for J1 and J2
every time a pulse is detected.
Compare Every 100 Pulses:
If the counters for J1 and J2
reach 100 pulses:
Calculate the difference: diff =
|J1 - J2|.
Reset counters for J1 and J2 to
zero.
Determine Operation Mode:
If diff is less than or equal to
2:
Set the mode to NO SLIP.
Set the status to TOGGLING.
If diff is greater than 2:
Set the mode to SLIP.
Set the status to ON.
Perform Operations Based on Mode:
If the mode is NO SLIP:
Execute operations as if the
machine is toggling.
If the mode is SLIP:
Execute operations as if the
machine is on.
Repeat the Process:
Go back to the main loop and keep
counting pulses, comparing, and performing operations.
AB3 LD
LAB3 FBD
LAB3 ST
LAB3 IL
LAB6
PLC Configuration
In Figure 7, the setup is displayed.
Figure7: PLC Configuration
Algorithm
Figure8: PLC Algorithm
Initialize Variables:
Set variables to track conveyor
status (moving or not moving).
Set variables to track the
direction of conveyor movement (right, left, or none).
Start the System:
Upon starting the program, the
conveyor is assumed to be not moving.
Place/Remove Items:
Items can be placed on or removed
from the conveyor only when it's not moving.
Move Conveyor to the Right (Ein
Rechts - E3/E4):
If Ein Rechts (E3 or E4) is pressed:
Check if the conveyor is not
moving.
If true, activate A1 (right
movement output) and set a timer for a 1.5-second delay.
Stop Conveyor (AUS - E1/E2):
If AUS (E1 or E2) is pressed:
Deactivate A1 and A2 (stop
movement outputs).
Automatic Stop by Light Barriers
(B1/B2):
If light barriers B1 or B2 detect an obstacle:
Deactivate A1 and A2 (stop
movement outputs).
Move Conveyor to the Left (Ein
Links - E5/E6):
If Ein Links (E5 or E6) is pressed:
Check if the conveyor is not moving.
If true, activate A2 (left
movement output) and set a timer for a 1.5-second delay.
Start Continuous Right Movement
(E7/E8):
If E7 or E8 is pressed:
Check if the conveyor is not
moving.
If true, activate A1 and set the
conveyor to continuously move to the right as long as E7 or E8 is pressed.
Automatic stop by B1 or B2.
Deactivate Manual Control (E7/E8):
If E7 or E8 is pressed:
Deactivate Ein Rechts (E3/E4) and
Ein Links (E5/E6) buttons.
Enable E7/E8 Only at Conveyor Halt:
E7/E8 can only be activated if the
conveyor is not moving.
Outputs A1 and A2:
A1 and A2 control the movements to
the right and left, respectively.
Repeat the Process:
The system continuously repeats
the conveyor control process based on user inputs and sensor feedback.
Putting it Together:
Users can place or remove items
only when the conveyor is not moving.
Buttons control movements: E3/E4
for right, E5/E6 for left, and E7/E8 for continuous right.
Conveyor stops automatically if
AUS is pressed or light barriers detect obstacles.
Manual control buttons (Ein
Rechts, Ein Links) are deactivated when continuous right movement is initiated.
E7/E8 can only be pressed when the
conveyor is at a halt.
LAB6 ST
LAB7
Configuration PLC
In Figure 9, the setup is
displayed.
Figure9: PLC Configuration
Algorithm
Figure10: PLC Algorithm
Initiation:
Press the "Freigabe"
button to start the process.
Box Placement and Bottle Transportation:
Upon pressing
"Freigabe," position the box and transport bottles to the filling
location.
Filling Process:
If the bottle reaches the filling
position:
Stop the conveyor immediately.
Lower the dosing head to the
appropriate level.
Valve Activation:
Activate the filling valve for a
specific duration (5 seconds) to fill the bottle.
Completion of Filling:
After the set time, the dosing
head ascends, indicating the completion of the filling process.
Bottle Transfer to the Box:
Move the filled bottle to the
designated box.
Cycle Reiteration:
Repeat the entire cycle with a
1-second delay before starting the next cycle.
Cycle Counting:
Keep track of the number of
cycles.
If 12 cycles are completed (12
filled bottles), proceed to the box replacement step.
Box Replacement:
Press the "Freigabe" button
again to initiate the box replacement process.
End of Algorithm:
The algorithm concludes, and the
system is ready for the next set of cycles.
LAB7 FBD
LAB8
In Figure 11, the setup is
displayed.
Figure11: PLC Configuration
Algorithm
Figure12: PLC Algorithm
Initialize Variables:
Set a variable to track the
current mode (Manual or Semi-automatic).
Initialize variables for log sizes
(small, medium, long).
Start the System:
Upon starting the program, logs
begin to move through three light barriers.
Log Sorting Process:
Logs are transported through the
light barriers for detection.
If a log is small, it goes to Box
1. If medium, it goes to Box 2. If long, it needs processing elsewhere.
Ensure Sequential Sorting:
The next log can only be taken if
the current log is sorted. Detection is performed by the light barriers.
Manual Mode:
If the system is in Manual Mode:
Logs are sorted when the start
button is manually pressed.
Long logs cannot be sorted even if
the button is pressed.
Semi-automatic Mode:
If the system is in Semi-automatic
Mode:
Short and medium logs are
automatically sorted after the start button is pressed.
Long logs are automatically
sorted.
Change Log Size Processing:
If a change is needed in log size
processing (e.g., different processing for long logs), the system should be
configured accordingly.
Repeat the Process:
The system continually repeats the
log sorting process, ensuring sequential sorting and adherence to the selected
mode.
Putting it Together:
Logs move through light barriers
for detection.
Based on the mode (Manual or
Semi-automatic), logs are sorted accordingly.
Long logs are processed elsewhere.
The system continuously repeats
the sorting process based on the selected mode.
LAB8 LD
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