PLC and Pneumatics

Group Assignment

Page 1 of 7

PLC and Pneumatics Assignment

Learning Outcome
1. Analyse and apply PLC control. 2. Provide detailed solutions to real control problems.

3. Analyse and applied pneumatic control to automation system. 4. Analyse and applied PLC control to automate pneumatic system

This assignment introduces the students to PLC programming and pneumatic circuit design. Students should be able to use PSIM simulator and demonstrate the PLC programming functions. Students should be able design pneumatic circuit and simulate the output with the Automation studio software.

APU Level 3

Asia Pacific University of Technology and Innovation

201210

PLC and Pneumatics

Group Assignment

Page 2 of 7

Tasks to be done This assignment consists of two parts which are individual component and group component are stated below:

Part 1: Lab experiment (Group component) i) ii) iii) iv) v) Lab 1 - DC motor speed and direction control Lab 2 - Rotational position system with DC motor and encoder Lab 3 - Stepper motor control for positioning Lab 4 Stepper motor speed control Lab 5 - Conveyor system to sort parts with different height

Part 2 (Group Component) i) Graphical based interface for PLC controlled automated bottle filling and capping system with user defined volume selection. ii) Graphical based information display using PLC interface.

APU Level 3

Asia Pacific University of Technology and Innovation

201210

PLC and Pneumatics

Group Assignment

Page 3 of 7

Part 1 (Lab Group Component) In this part OMRON PLC will be used to control real life automation application. The devices that can be controlled are motor and sensors. Students are to perform the 5 given task below. 1) DC motor speed and direction control For this task a 12V DC motor with a motor driver must be connected to the PLC as shown in Figure 3.

DC motor

DC motor driver

PLC

Figure 3 The programming sequence i) The DC motor must have 3 different speed controls by using 3 different switches. ii) The DC motor must be able to rotate counter clockwise (CCW) and clockwise (CW) using 2 switches. iii) The system must also have a single start and stop switch. 2) Rotational position system with DC motor and encoder For this task a 12V DC motor and encoder with a motor driver must be connected to the PLC. The programming sequence i) The DC motor must have 3 different positions by using 3 different switches. ii) The encoder is used to detect the positions. iii) The DC motor must be able to rotate counter clockwise (CCW) and clockwise (CW) using 2 switches. iv) The system must also have a single start and stop switch. 3) Stepper motor control For this task a 12V stepper motor with a motor driver must be connected to the PLC. The programming sequence i) The stepper motor must have 3 different positions by using 3 different switches. ii) The stepper motor must be able to rotate counter clockwise (CCW) and clockwise (CW) using 2 switches. iii) The system must also have a single start and stop switch. iv)
APU Level 3 Asia Pacific University of Technology and Innovation 201210

PLC and Pneumatics

Group Assignment

Page 4 of 7

4) Stepper motor speed control with acceleration and deceleration For this task a Stepper motor is used with the stepper motor driver which is connected to the PLC as shown in the Figure 3. The programming sequence i) The stepper motor must have 3 different speed controls which are acceleration speed, constant speed and the deceleration. ii) The sample speed curve for the stepper motor is shown in Figure 4. iii) The stepper motor must be able to rotate counter clockwise (CCW) and clockwise (CW) using single switch. iv) The system must also have a single start and stop switch. Speed Constant speed

Acceleration

Deceleration

Figure 4 5) Conveyor system to sort different height of parts

Time

For this task a 12V DC motor and a motor driver and sensor must be connected to the PLC as shown in Figure 5 below. Rejection mechanism Parts High sensor Low sensor DC Motor

Figure 5 The programming sequence i) The DC motor must have 2 different speeds by using 2 different switches. ii) The sensor is used to detect the high and low parts. The low part goes through the system will the high part is rejected. iii) The system must stop when 3 low parts are detected and the part must stop at the end of the conveyer. iv) The system must also stop when 3 high parts are rejected. v) The system must also have a single start and stop switch. vi) The system must also have a reset switch to continue the cycle once the counter is reset.
APU Level 3 Asia Pacific University of Technology and Innovation 201210

PLC and Pneumatics

Group Assignment

Page 5 of 7

Part 3 (Group Component) i) Graphical based interface for PLC controlled automated bottle filling and capping system with user defined volume selection. The system is made up of the component listed in Figure 6. The bottling and capping system consists of component listed below: a) b) c) d) e) Conveyer with DC motor Concentrate tank with 1 pump Water tank with 1 pump Process tank with 3 pumps Capping actuator pneumatic

The inputs and output are listed in table 1 below:

Input 4 IR Sensor (for bottle detection) 3 Level sensor HI 3 Level sensor LOW Output 5 Pumps 1 Solenoid valve 1 DC motor Start switch Emergency switch

Table 1 Filling operation The filling operation will commence after the bottle is detected. The respective pumps will be turned on and the bottles are filled. If the bottle is not present the will not be switched on. When the tank is low the water and concentrate pump will be switched on. When the water or the concentrated is low and alarm is activated. The bottles can be filled according to the sequences in table 2 below:
Sequence 1 2 3 4 Bottle 1 1 0 0 1 Bottle 2 1 1 0 0 Bottle 3 1 1 1 1

Table 2 The sequence below has to be solved using shift register method. User defined volume The volume of the liquid o be filled up in the bottle is decided by the user. The user can select the volume form the GUI interface system. The preset values of ratio for the volume of water and concentrate can also be decided by the user.
APU Level 3 Asia Pacific University of Technology and Innovation 201210

PLC and Pneumatics

Group Assignment

Page 6 of 7

The capping operation The capping process will begin when the bottle is detected. The actuator will be on for 3 second and retracted back. The GUI information system i) ii) iii) iv) v) The GUI must display the total volume of each liquid used. The total bottles filled. The information regarding the user selection of the liquid quantity and liquid ratio. Tank filling animation, bottle full, capping of bottle and actuator movement. Conveyer and bottle movement.

Concentrate tank

Water tank

Pump 5 Process tank

Pump 4

Capping actuator

Pump1 Pump2 Pump3

IR Sensor 1

DC motor 1 (conveyer) Figure: 6

Input button for selection storage

APU Level 3

Asia Pacific University of Technology and Innovation

201210

PLC and Pneumatics

Group Assignment

Page 7 of 7

Marks distribution i) Individual Component i) Report format Referencing, labeling of figures and tables, Contest pages must be describe well. (5%) ii) Report A report also has to be submitted at the end of the assignment. Report Format o Introduction Discuss the background and similar existing system o Objective o PLC motor control application (Lab) Connection diagram given Programming is explained Flow chart given and explanations given for each of the method Discussion and Conclusion o Bottling system design using PLC control GUI for the Automation system design given Control of component explained with GUI interface Ladder diagram explained with Flow charts o Discussion and Conclusion (25%) ii) Group Component (Motor control lab) 25% i) Students able to show the results (10%) ii) Students able to explain the connection to the PLC (5%) iii) Students able to explain the programming logic used (10%) iii) Group Component (45%) i) Bottling Automation system design. The design in presented with GUI. (10%) ii) Bottling Automation design should be shown in report and explain the circuit working. Show the simulation working with the CX designer software. (15%) iii) Explain how PLC is interfaced with PC GUI to achieve the control simulation of Bottling Automation system. (15%) iv) Discussion and conclusion (5%)
APU Level 3 Asia Pacific University of Technology and Innovation 201210