ENT471 Automation School of Mechatronics engineering Exp 4 Laboratory

Module

Marks

AUTOMATION

ENT471

Session 2010/2011
Semester 1

Experiment No. 4

PLC Programming & Application

Name : ___________________________________________

Matric No. : ___________________________________________

Experiment Date : ___________________________________________

Report Submission Date : ___________________________________________

Received By : ___________________________________________

School of Mechatronics Engineering

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 ENT471 Automation School of Mechatronics engineering Exp 4 Laboratory
Module

Universiti Malaysia Perlis

EXPERIMENT 4

PLC Programming & Application

Objective:

To program Omron CPM1A PLC using CX-programmer software.

To design and simulate PLC special instruction to perform industrial application.

Timer and Counter

Timer is an instruction that waits a set amount of time before doing something. Timer is
normally used for time delay. It can be ON delay or OFF delay.
1) ON Delay timer
After input turns ON, the system wait x-seconds before activating output.

2) OFF Delay timer

When the input no longer sees the target, the output holds on for x-seconds before
turning its OFF.

Counter is to capture and store number of occurrence. There are two inputs of a counter –
one called the ‘count line’ and another is called ‘reset line’. When there is an input transition
from OFF to ON at counter line, counter will start counting and when there is an input
transition at reset line, the counter resets zero (0).

Experiment 4(a)

The control circuit is used to detect and count the number of products being carried on an
assembly line. When the sensors (00000) count 5 products, the conveyor motor (01000) will
stop and PLC output (01001) will energize the solenoid and activate a cylinder. The cylinder
will push the products to packaging station. The solenoid is energized for a period of three
seconds and is the shunt off, causing the cylinder to retract.

Fig. 4(a)

I/O Assignment
Input Devices Output Devices Others
00000 Sensor 01000 Conveyor CNT001 Product counter

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01001 Solenoid TIM 002 Solenoid timer

Ladder 4(a)

1) Create new PLC program to demonstrate Timer & Counter functions for above
application.
2) Complete all contact address, coil address, counter value and timer value to
perform the packaging application.

KEEP and Differentiation (DIFU & DIFD)

KEEP is used as a latch. It maintains an ON or OFF state of a bit until one of its two inputs
sets or resets it.

Ladder diagram Mnemonic code

Address Instructions Data
0000 LD 0000
0001 LD 0001
0002 KEEP(11) 1000
0003 LD 1000
0004 OUT 1001

Timing diagram

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DIFU and DIFD turn an output ON for one scan

only.

DIFU turns its output when it detects an

OFF  ON transition in its input signal.

DIFD turns its output when it detects an

ON  OFF transition in its input signal

Experiment 4 (b)

The input ultrasonic switch is employed to detect the presence of an approaching vehicle. A
separate photosensor detects the passing of a vehicle via the interruption of the light beam.
In response to these signals, the control circuit controls the outputs that drive the motor of
the door for opening and closing. Ultrasonic
switch Motor

Push Button
Photoelectric
sensor

CPM1A PLC

Fig. 4(b)

I/O Assignment
Input Devices Output Devices
00000 Ultrasonic switch 01000 Motor to raise door
00001 Photoelectric switch 01001 Motor to lower door
00002 Door Upper limit switch
00003 Door Lower limit switch

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Ladder 4(b)

1) Create new PLC program using CX-programmer to demonstrate above application by

completing above Ladder diagram.

Task of Week for PLC

1) Conveyor Belt Motor Control

Motor 3

Motor 2

Motor 1

CPM1A PLC

Fig. 4(c)

The PLC is used to start and stop the motors of a segmented conveyor belt. This allows only
belt sections carrying a copper plate to move. A proximity switch located next to each belt
segment detects the position of copper plate. As long as the plate is within the detecting

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range of the switch the motor will work. If the plate moves beyond the range, a timer is
activated and when this set time has elapsed, the motor of that belt stops.

I/O Assignments
Input Devices Output Devices
00001 Sensor 1 01001 Motor 1
00002 Sensor 2 01002 Motor 2
00003 Sensor 3 01003 Motor 3

Operation:
a) Motor 2 turns ON when Sensor 3 detect the copper plate
b) Motor 2 is ON until Motor 1 is turned ON and copper plate is out of detection range of
Sensor 2
c) Motor 1 turns ON when Sensor 2 detects the copper plate
d) Motor 1 is ON until copper plate is out of detection range of Sensor 1.

2) Filling/Draining Control Operation

Fig 4(d)

I/O Assignments
Input Devices Output Devices

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00000 Start Button 01000 Water Supply

(PB1) Valve (MV1)
00001 Stop Button 01001 Drain Valve
(PB2) (MV2)
00002 Reset Button 01002 Stirring Motor (M)
(PB3)
00005 Upper Level 01004 End Indicator
Sensor (TLB1)
00006 Lower Level 01005 Buzzer
Sensor (TLB2)

Operation
a) As the PB1 is pressed, MV1 opens and water begins to fill the tank. At the same time
stirring motor M starts operation
b) When water level passes TLB2 and TLB1, the MV1 closes and stirring motor stop.
c) Next, MV2 opens and starts draining the water. When the water level drops below
TLB2 MV2 closes.
d) When the cycle of operation has repeated four times, the end indicator illuminate and
after 2 seconds activated the buzzer.

LAB REPORT 4

PLC Programming & Application

PLV/ Lecturer Simulation &

CX program
sign column Explanation
Exp 4(a) :
/ 10 /5
Timer & Counter
Exp 4(b) : KEEP,
/ 10 /5
DIFD and DIFU

Task of the week

Your submitting Lab’s report MUST included of following items.

1. Process flow and Timing diagram

Marks
Task 1
/ 10
Task 2
/ 10

2. Ladder diagram using CX-programmer

Marks
Exp 4(a)
/5
Exp 4(b) /5

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Module

Task 1
/ 10
Task 2
/ 10

3. Mnemonic code
Marks
Exp 4(a)
/5
Exp 4(b)
/5
Task 1
/5
Task 2
/5

Total Marks: / 100

Instructor Approval: ___________________________ Date: ____________

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