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    PLC Exercises LD

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    txr qc
    The document describes several exercises for building ladder logic diagrams to control pneumatic and mechanical processes. It provides details on 7 exercises involving moving pneumatic pistons, sequencing multiple pistons, batch counting components, detecting and rejecting faulty components, a pick and place unit, organizing a production line, and controlling a star-delta motor connection. For each exercise, common issues that could cause the system not to work properly are discussed, such as incorrect wiring, non-functioning devices, or errors in the ladder logic programming.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    PLC Exercises LD

    Uploaded by

    txr qc
    176 views27 pages
    The document describes several exercises for building ladder logic diagrams to control pneumatic and mechanical processes. It provides details on 7 exercises involving moving pneumatic pistons, sequencing multiple pistons, batch counting components, detecting and rejecting faulty components, a pick and place unit, organizing a production line, and controlling a star-delta motor connection. For each exercise, common issues that could cause the system not to work properly are discussed, such as incorrect wiring, non-functioning devices, or errors in the ladder logic programming.

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    PLC-Exercises-LD

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    The document describes several exercises for building ladder logic diagrams to control pneumatic and mechanical processes. It provides details on 7 exercises involving moving pneumatic pistons, sequencing multiple pistons, batch counting components, detecting and rejecting faulty components, a pick and place unit, organizing a production line, and controlling a star-delta motor connection. For each exercise, common issues that could cause the system not to work properly are discussed, such as incorrect wiring, non-functioning devices, or errors in the ladder logic programming.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    176 views27 pages

    PLC Exercises LD

    Uploaded by

    txr qc
    The document describes several exercises for building ladder logic diagrams to control pneumatic and mechanical processes. It provides details on 7 exercises involving moving pneumatic pistons, sequencing multiple pistons, batch counting components, detecting and rejecting faulty components, a pick and place unit, organizing a production line, and controlling a star-delta motor connection. For each exercise, common issues that could cause the system not to work properly are discussed, such as incorrect wiring, non-functioning devices, or errors in the ladder logic programming.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 27

    PLC Exercises

    Ladder Diagram
    Programming

    By

    Dr. Mohammad Salah


    Mechatronics Engineering Department
    Hashemite University
    Dr. Mohammad Salah – Mechatronics

    Steps for Building a Ladder Diagram

    1. Determine the No. of digital I/O


    2. Determine the No. of analog I/O (if needed)
    3. Determine if there are special functions in the process
    4. Estimate program capacity depending on the process
    5. Choose a suitable PLC series
    6. Prepare the wiring diagram
    ٢ 7. Draw flowchart or control diagram (Optional)
    8. Program the PLC using the ladder diagram
    Dr. Mohammad Salah – Mechatronics

    Exercise #1: Moving a Pneumatic Piston

    Control Problem
    The PLC task is to move the
    piston in and out. When
    switch SW1 is momentarily
    turned on, piston A is to
    move out of the cylinder in
    A+ direction. When switch
    ٣ SW2 is momentarily turned
    on, piston A is to move into
    the cylinder in A- direction.
    Dr. Mohammad Salah – Mechatronics

    Exercise #1: Moving a Pneumatic Piston

    ٤
    Dr. Mohammad Salah – Mechatronics

    Exercise #1: Moving a Pneumatic Piston

    If SW1 and SW2 are


    pressed together,
    what would happen?

    The two solenoid


    valves will be tuned off

    How can we make


    ٥ an electrical
    interlock?

    Use the contacts of the


    main relays instead of
    the input contacts
    Dr. Mohammad Salah – Mechatronics

    Exercise #2: Sequencing of Pneumatic Pistons

    Control Problem
    The PLC task is to operate piston A followed by
    piston B followed by piston C. The sequence is A+,
    A-, B+, B-, C+, C- is to be repeated when switch
    SW1 is turned on
    Dr. Mohammad Salah – Mechatronics

    Exercise #2: Sequencing of Pneumatic Pistons

    ٧
    Dr. Mohammad Salah – Mechatronics

    Exercise #2: Sequencing of Pneumatic Pistons

    ٨
    If the system does not work or sequence in not
    correct, what would be the possible reasons?
    • Solenoid valves do not work
    • The wiring of solenoid valves is not correct or not in
    the correct order (wiring problem)
    • The ladder diagram is not properly written (sequence
    in not correct)
    Dr. Mohammad Salah – Mechatronics

    Exercise #3: Batching Machine

    Control Problem
    The PLC task is to control a simple
    ٩ machine which counts and batches
    components moving along a conveyor. It
    is required that ten components be
    channeled down route A and twenty
    components down route B. A reset facility
    is required
    Dr. Mohammad Salah – Mechatronics

    Exercise #3: Batching Machine

    ١٠
    Dr. Mohammad Salah – Mechatronics

    Exercise #3: Batching Machine

    ١١
    Dr. Mohammad Salah – Mechatronics

    Exercise #3: Batching Machine

    If the system does not batch and/or


    count, what would be the possible
    reasons?

    • The reset switch is always on


    • The microswitch does not work
    • The flap solenoid does not work
    • The ladder diagram is not properly
    written
    ١٢
    Dr. Mohammad Salah – Mechatronics

    Exercise #4: Reject Machine

    ١٣ Control Problem
    The PLC task is to detect and reject faulty components. Components are
    transported on a conveyor past a retro-reflective type photoelectric switch. The
    photoelectric switch is positioned at a height (H) above the conveyor where (H)
    represents a tolerance value for component height. Good components pass
    underneath the photoelectric switch and no signal is generated. Faulty
    components break the light beam twice as they pass the photoelectric switch.
    Dr. Mohammad Salah – Mechatronics

    Exercise #4: Reject Machine

    ١٤
    Dr. Mohammad Salah – Mechatronics

    Exercise #4: Reject Machine

    ١٥
    Dr. Mohammad Salah – Mechatronics

    Exercise #4: Reject Machine

    ١٦
    If the system does not reject faulty components, what would be the
    possible reasons?
    • The photoelectric switch is too high (H is too big)
    • The photoelectric switch does not work
    • The pneumatic blower does not work
    • The ladder diagram is not properly written
    • The faulty components is not as described in the drawing
    Dr. Mohammad Salah – Mechatronics

    Exercise #5: Pick and Place Unit

    ١٧
    Control Problem
    The PLC task is to:
    a) move the gripper to X+ position
    b) close the gripper so that it takes hold of a component
    c) rotate the gripper through 180o to the Θ+ position
    d) Release the component
    e) Rotate the gripper back to the Θ- position so that the pick and place
    operation may be repeated
    Dr. Mohammad Salah – Mechatronics

    Exercise #5: Pick and Place Unit

    ١٨
    Dr. Mohammad Salah – Mechatronics

    Exercise #5: Pick and Place Unit

    If the system does not


    work or sequence is not
    correct, what would be
    the possible reasons?
    • Wiring problem
    • Some solenoid valves do
    not work
    • Timing is not correct
    • The ladder diagram is
    ١٩
    not properly written
    (sequence in not correct)

    How can we get rid of the timers in the ladder diagram/program?


    Use position sensors for feedback but that would be expensive compared to
    using timers but more accurate and reliable in case the mechanical system
    starts to have some problems
    Dr. Mohammad Salah – Mechatronics

    Exercise #6: Production Line

    ٢٠ Control Problem
    The PLC task is to organize the production process. Cans filled with fluid and
    capped before passing into a conveyor. The photoelectric switches P1 and P2 are
    used to check that each can has a cap. Photoelectric switch P3 provides a trigger
    for the ink jet printer which prints a batch number on each can. Photoelectric
    switch P4 is used to count three cans into the palletizing machine that transports
    three cans through a machine which heat shrinks a plastic wrapping over them.
    All photoelectric switches on the production line are of the retro reflective type.
    Dr. Mohammad Salah – Mechatronics

    Exercise #6: Production Line

    ٢١
    Dr. Mohammad Salah – Mechatronics

    Exercise #6: Production Line

    ٢٢
    Dr. Mohammad Salah – Mechatronics

    Exercise #6: Production Line

    ٢٣
    If the system allows uncapped cans to pass, what would be the
    possible reasons?
    • The height of the photoelectric switch needs to be readjusted
    • The photoelectric switch does not work (transmitter or receiver)
    • The photoelectric transmitter is not aligned with the receiver
    • The ladder diagram is not properly written (or timer is not set properly)
    Dr. Mohammad Salah – Mechatronics

    Exercise #7: Star-Delta Connection

    ٢٤
    Dr. Mohammad Salah – Mechatronics

    Exercise #7: Star-Delta Connection

    ٢٥
    Dr. Mohammad Salah – Mechatronics

    Exercise #7: Star-Delta Connection

    ٢٦

    PLC system layout – Wiring diagram


    Dr. Mohammad Salah – Mechatronics

    Exercise #7: Star-Delta Connection

    ٢٧

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