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Assignment 1

1. The document provides 14 examples of PLC logic programs for various industrial processes including: controlling multiple machines, a conveyor system, analog input sampling, temperature control in a tank, part counting, timer use, light switching, temperature data logging, oven temperature control, traffic light sequencing, spray painting, product inspection on an assembly line, liquid heating control, PID loop control, and tank filling/emptying control. Diagrams and descriptions are given for each process and the goal is to design the corresponding ladder logic program.

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Karthik Vyas
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© © All Rights Reserved
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571 views

Assignment 1

1. The document provides 14 examples of PLC logic programs for various industrial processes including: controlling multiple machines, a conveyor system, analog input sampling, temperature control in a tank, part counting, timer use, light switching, temperature data logging, oven temperature control, traffic light sequencing, spray painting, product inspection on an assembly line, liquid heating control, PID loop control, and tank filling/emptying control. Diagrams and descriptions are given for each process and the goal is to design the corresponding ladder logic program.

Uploaded by

Karthik Vyas
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Logic and Distributed Control Systems

B.Tech (ICE) DoS 27 Sep 2021


1. There are three machines, each with its own start and stop buttons. Any two machines may
run at one time (also, any one may run by itself). Each start button is to have a sealing circuit.
Construct a PLC circuit with appropriate interlocking for this problem.
2. Assume there are sixteen stations along a conveyor system. The stations are numbered from
0-15 with station zero being the first (i.e. the point where parts enter the conveyor). Parts are
to advance along the conveyor at the rate of one station every four seconds. A part may or may
not be at a given station at any point in time. An input sensor I:0.0/0 is used to detect a part
entering the conveyor. At station 5, parts are checked for defects and an input sensor I:0.0/1 is
energized if the part is defective. At station 10, any defective parts are to be removed from the
conveyor by energizing output O: 0.0/0.Write an efficient ladder logic program for this
process.
https://instrumentationtools.com/plc-program-for-conveyor-system/
3 Design an efficient ladder logic program that samples analog input (I:1.0) at the rate of 2Hz
and outputs the average value to analog output O:1.0 once every two seconds.
https://instrumentationtools.com/plc-program-for-analog-input-sampling/
4. Heat the process fluid to a temperature of 80°C and stir it for 5 minutes. Allow the fluid to
settle for another 20 minutes before it gets dried up. The level is to be maintained at L2. State
the necessity of having the limit switch LS1. The problem for the given system is illustrated in
figure 1.

Fig. 1. Temperature control of a sequential process in a single


tank

5. Design the ladder diagram for a device that will count parts as they pass by an inspection
stand. The sensing device for the PLC is a switch that will close each time a part passes. This
switch is connected to IN1 of the PLC. A reset switch, IN2, is also connected to the PLC to
allow the operator to manually reset the counter. After 15 parts have passed the inspection
stand, the PLC is to reset the counter to again begin counting parts and turn on a light which
must stay on until reset by a second reset switch connected to IN3. The output from the PLC
that lights the light is OUT111. 7. Design the ladder diagram for a program which needs a timer
which will cause a coil CR24 to energize for one scan every 5.5 seconds.
6. It is desired to implement a switch system similar to a three-way switch system in house
wiring, that is, a light may be turned on or off from either of two switches at doors on opposite
ends of the room. If the light is turned on at one switch, it may be turned off at the other
switch
and vice versa. Draw the ladder logic rung which will provide this. Define the two switches
and IN10 and IN11 and the output which will control the light as OUT18.

7. Write a program for the following: The temperature reading from a thermocouple is to be
read and stored in a memory location every 5 minutes for 4 hours. The temperature reading is
brought in continuously and stored in address N7:150. File #7:200 is to contain the data from
the last full 4-hour period.

8. Devise a ladder logic program of how the MUL instruction is used as part of an oven
temperature control program. The operation of the program can be summarized as follows:
• The PLC calculates the upper and lower dead band, or off/on limits, about the set-point.
• Upper and lower temperature limits are set automatically at 61 percent regardless of the set-
point value.
• Set-point temperature is adjusted by means of the thumbwheel switch.
• The analog thermocouple interface module is used to monitor the current temperature of the
oven.
• In this example, the set-point temperature is 400°F.
• Therefore, the electric heaters will be turned on when the temperature of the oven drops to
less than 396°F and stay on until the temperature rises above 404°F.
• If the set-point is changed to 100°F, the dead band remains at 61 percent, with the lower limit
being 99°F and the upper limit being 101°F.
• The number stored in word N7:1 represents the upper temperature limit, and the number
stored in word N7:2 represents the lower limit.

9. To illustrate the purpose and function of the sequencer file we will examine the operation of
the four-step sequence process shown in Fig. 2 . This sequencer is to be used to control traffic
in two directions.

Figure. 2 Traffic Light Control

10. The process of Figure. 3 illustrates a spray-painting operation. Write a ladder logic for
the same.
Figure. 3 Spray-painting operation
11. A product moves continuously down an assembly line that has four stations, as shown
in Figure. 4.
• The product enters the inspection zone, where its presence is sensed by the proximity switch.
• The inspector examines it and activates a reject button if the product fails inspection.
• If the product is defective, reject status lights come on at stations 1, 2, and 3 to tell the
assembler to ignore the part.
• When a defective part reaches station 4, a diverter gate is activated to direct that part to a
reject bin.
• Using whatever PLC bit shift register you are most familiar with, develop a program to
implement this process.

Figure. 4 Assembly line


12. Figure 5 shows a system using on/off control in which a liquid is heated by steam. The
operation of the process can be summarized as follows:
• If the liquid temperature goes below the set-point, the steam valve opens and the steam is
turned on.
• When the liquid temperature goes above the set-point, the steam valve closes and the
steam is shut off.
• The on/off cycle will continue as long as the system is operating.
(a) Discuss how would an on/off controller respond if the dead band were too narrow?
(b) In a home heating system with on/off control, what will be the effect of widening the dead
band?
Figure. 5 On/off controlled liquid heating system.

13. Figure. 6 illustrates how a programmable logic controller can be used in the control of
a PID loop. The operation of the PID loop can be summarized as follows:
• The process variable (pressure) is measured and feedback is generated.
• The PLC program compares the feedback to the set point and generates an error signal.
• The error is examined by the PID loop calculation in three ways: with proportional, integral,
and derivative methodology.
• The controller then issues an output to correct for any measured error by adjustment of the
position of the variable flow outlet valve.

Figure. 6 PLC control of a PID loop.

14. Devise a ladder logic program for tank filling and emptying operation as shown in Figure.

Figure. 7 Tank filling and emptying Process

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