HLC. BTEC.

Assessment Center Number 024150

Course: BTEC Extended Diploma in Student:

Manufacturing Engineering / Diploma in
Electrical / Electronic Engineering

Unit/s:
Unit 25: Selection & Application of Programmable Logic Controllers
Outcome/s: (2) Produce a PLC program

Grading criteria:
P3 Use a programmable technique to produce, store and present a program that demonstrates the
full range of instruction types.
P4 Explain the program documentation that has been used for a complex engineering application.
M2 Justify the choice of a specific programming method and the methods used to produce, store
and present the program.
D1 Evaluate program documentation used to control an automated machine/process and make
recommendations for improvement.
D2 Compare the current capabilities and limitations of a programmable controller and identify
possible areas of future development.

Pass: Merit: Distinction:

Instructions:
• Attempt all questions
• Work to be word processed, legible and succinct, with an adequate grasp
of grammar, punctuation and spelling
• Ensure sketches & diagrams are clear, accurate & labelled
• True graphs, titled & axes labelled
• List sources where appropriate.

Student feedback:

Student declaration – The assignment attached is my own work.

Signed: Date:

Assessor feedback:

Signed: Date:

Internal verification Issue date Student hand in date Internal verification

(Before issue) (assessment decision)
CR 10/9/11
TUTOR R.A.KERSHAW.

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Assignment - PLC Programming.docx
HLC. BTEC. Assessment Center Number 024150

Grading Criteria and Feedback

P3 Use a programmable technique to produce, store and present a

program that demonstrates the full range of instruction types.

P4 Explain the program documentation that has been used for a complex
engineering application.

M2 Justify the choice of a specific programming method and the

methods used to produce, store and present the program.

D1 Evaluate program documentation used to control an automated

machine/process and make recommendations for improvement.

D2 Compare the current capabilities and limitations of a programmable

controller and identify possible areas of future development.

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Assignment - PLC Programming.docx
HLC. BTEC. Assessment Center Number 024150

Assignment - PLC Programming

This practical and written assignment provides evidence for satisfaction of

the Grading Criteria P3 and P4, and the opportunity to achieve M2, D1 and D2.

Using your class notes, the Bytronic Ladsim PLC application and any other
suitable resource, attempt all of the following tasks. (The relevant learning
outcome is given in brackets after each task)

Programming Tasks

You are to design and produce PLC program for the Bytronic Industrial Control
Trainer (ICT), as described in the Ladsim manual available on the course wiki.

The purpose of the machine is to sort two components, a metal body with a
peg and a plastic ring. The ring is assembled on to the peg and the finished
assembly is inspected with components not assembled being rejected.

The programming task details five independent tasks that are need to make
the machine work. You should design, develop and test each program
separately and then combine then into a single program.

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HLC. BTEC. Assessment Center Number 024150

Evidence Required

a. Either a flowchart, truth table, or logic functional block diagram for

each section, which ever is the most suitable for that section (at least
one example of each must be produced)
b. A complete ladder program with comments, to be demonstrated to your
tutor
c. A hard copy of your complete program. This is to include the ladder
and statement versions plus the comments

Input / Output Definitions

Inputs
Label Name Non-detection state
IP0 Metal Peg Detect Low
IP1 Sort Area Low
IP2 Hopper Full Low
IP3 Ring Assembled High
IP4 Component Detect High
IP5 Reject Area Low
IP6 Start Low
IP7 Stop High
IP8 Belt Peg Detect Low

Outputs
Label Name
OP0 Chain Motor (upper conveyor motor)
OP1 Sort Solenoid (ejects rings into chute)
OP2 Rotary Solenoid (allows rings in to hopper)
OP3 Reject Solenoid (ejects faulty components)
OP4 Belt Motor (lower conveyor motor)

Program 1 – Start & Stop

Use the Start and Stop buttons IP6 and IP7 to activate and deactivate both
the chain conveyor OP0, and the belt conveyor OP4.

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Program 2 – Sorting

Use the Metal Peg Detect IP0 and Sort Area IP1 sensors at the sorting area
to determine the identity of the item and by activating the Sort Solenoid OP1,
sort the rings into the ring chute. Pegs should be allowed to pass, enabling
them to continue down onto the belt conveyor.

Program 3 – Assembly Chute

Use a counter to record the number of

rings in the chute: when full (5 rings in
queue), no further rings should be added.

Activate the Rotary Solenoid OP2 to

dispense rings into the assembly hopper
when the Hopper Full sensor IP2
indicates that it is empty.

Program 4 – Inspection

Use the Belt Peg Detect sensor IP8 and

the Ring Assembled sensor IP3 to
determine whether the component is a
correctly assembled part.

If the components are not assembled

correctly then a flag may be used to
register this for later use in the reject
area.

Use the Component Detect sensor IP4 to detect anything passing out of the
assembly area.

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Program 5 – Rejection

Use the Reject Area sensor IP5 to detect when a part is at the reject area
and determine from the data captured previously whether the component
needs to be accepted or rejected (i.e. it’s a ring or a peg on its own). Operate
the Reject Solenoid OP3 to knock the rejected components off the conveyor.

(P3, P4)

Written Tasks

1. Flowcharts, Truth tables and logic function diagrams are used to design
PLC programs. Briefly explain the advantages and disadvantages of each
method; you may give examples where one method might be more useful
than another.
(M2)

2. Define the meaning of the terms “offline” and “online” programming in

relation to PLCs, and discuss the advantages and disadvantages of both
methods.
(M2, D2)

3. Discuss the methods used to debug PLC programs and explain the
usefulness and limitations of each method.
(D1, D2)

4. When a program is transferred from a PC to a PLC or a programming panel

is used to transfer the program, you are given an option to compare your
program after transfer. Explain what this means and why it is important.
(D1)

Unit 25: Selection and Application of Programmable Logic Controllers Page 6 of 6

Assignment - PLC Programming.docx