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PLC Exercises PDF

The document describes several automation examples involving PLC programming for different processes: 1. A central heating system controlled by a PLC that operates boilers, pumps, and valves based on sensor inputs and a clock timer. 2. An automatic mixing station that sequences valves and motors to mix liquids for a set time and transfer the output to a storage tank. 3. A door testing system for trains that opens and closes doors 1000 times and simulates obstructions every 5 cycles.

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1K views

PLC Exercises PDF

The document describes several automation examples involving PLC programming for different processes: 1. A central heating system controlled by a PLC that operates boilers, pumps, and valves based on sensor inputs and a clock timer. 2. An automatic mixing station that sequences valves and motors to mix liquids for a set time and transfer the output to a storage tank. 3. A door testing system for trains that opens and closes doors 1000 times and simulates obstructions every 5 cycles.

Uploaded by

zoulouwe
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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EXERCISES

Example (Central Heating)


Consider a central heating system with the
following features :

The

boiler is

thermostatically

controlled

and

supplies the radiator system in addition to a hot


water tank.

Pumps

are used to supply hot water to either or

both the radiator and the tank according to the


desired sensors.

The

whole system is controlled by a clock to

operate a certain time a day.

Motorized
Pump

Radiator
System

M1
Hot water
tank
Boiler
M2
Motorized
Pump

Boiler Temp.
sensor

Hot water tank


Temp. sensor

Room
Timers

The power circuit for the central heating


system is :

Stop

Power

Run

Room sensor
Tank sensor

Outputs

Boiler sensor

Inputs

Clock

Boiler
M1

M2

The ladder & IL program for the central heating


system using Mitsubishi PLC is :

Inputs :
X400

Clock

X401

Boiler sensor

X402

Room sensor

X403

Tank sensor

Outputs :
Y430

Boiler

Y431

Pump M1

Y432

Pump M2

Step

X402

X400

X401

Y430

X403

Y430

Y430

X402

Y431

X403

Y432

END

Instruction

LD

X402

OR

X403

AND

X400

AND

X401

OUT

Y430

LD

Y430

AND

X402

OUT

Y431

LD

Y430

AND

X403

10

OUT

Y432

11

END

The ladder & IL program for the central heating


system using Siemens PLC is :

Inputs :
I0.0

Clock

I0.1

Boiler sensor

I0.2

Room sensor

I0.3

Tank sensor

Outputs :
Q2.0

Boiler

Q2.1

Pump M1

Q2.2

Pump M2

Step

I0.2

I0.0

I0.1

Q2.0

I0.3

Q2.0

Q2.0

I0.2

Q2.1

I0.3

Q2.2

END

Instruction

I0.2

I0.3

I0.0

I0.1

Q2.0

Q2.0

I0.2

Q2.1

Q2.0

I0.3

10

Q2.2

11

END

Example (Timer Application)


Automatic mixing processes of

liquids

and

other

compounds in the chemical and food industries are very


common.

The mixing station goal is to mix two liquids for a


specified time and then output the final product to a
storage tank.

The system consists of :

1. Two level sensors to monitor the flowing of the


liquids into the tank.

2. Three solenoid valves to control the flow of liquids.


3. A motor connected to an agitator to mix the liquids
into the tank.

Input Valves

VA2
VA1

MS1
Motor & Agitator

Mixing Tank

LS1
Level Sensors

LS2

Mixing
Station

VA3

Output to Storage Tank

The sequence of events for this automatic mixing process will


be as follows :

1. Open valve 1 until level 1 is reached for the first liquid .


2. Then close valve 1 .
3. Open valve 2 until level 2 is reached for the second
liquid .

4. Then close valve 2 .


5. Start the motor and agitate to mix the liquids into the
tank for a specified time .

6. Then stop the motor .


7. Open valve 3 up to a specified time to empty the mixed
product to a storage tank .

8. Then close valve 3 .


9. Repeat or end the mixing process as required .

The

automatic

mixing

station

will

components using Mitsubishi PLC :

1. Inputs to the PLC :


Start push button

X400

Stop push button

X401

Level sensor LS1

X402

Level sensor LS2

X403

1. Outputs from the PLC :


Valve # 1 (VA1)

Y430

Valve # 2 (VA2)

Y431

Motor starter (MS1)

Y432

Valve # 3 (VA3)

Y433

require

the

following

I0.0

I0.1

F0.1

F0.1
F0.1

I0.2

I0.3

Q2.2

Q2.3
Q2.0

F0.1

I0.2

I0.3

Q2.2

Q2.3
Q2.1

I0.3

F0.1

T0
KT1200
I0.3

F0.1

F0.2

F0.2
Q2.2

F0.1

Q2.3
F0.1

F0.2

T1

F0.3

KT180
F0.1

F0.3

F0.2
END

Q2.3

Counter Application
Consider the following packing machine,
where it is required to pack 6 objects in a
box and then pack 12 objects in another
box in another path as shown :

12 in box

6 in box

X400

RESET
C461

C460
K6

X401
Out
C460

Y430

X400
RESET

C461

X401

C461
K 12
C460
Out

C461

Y431

Step
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

Instruction
LD
X400
OR
C461
RST
C460
K
6
LD
X401
OUT
C460
LD
C460
OUT
Y430
LD
X400
OR
C461
RST
C461
K
12
LD
X401
AND
C460
OUT
C461
LD
C461
OUT
Y431
END

Mitsubishi PLC program

Exercise
A door system for trains is tested by opening
and closing the doors about 1000 times and on
every fifth closing of the doors, a pneumatic
cylinder out-strokes to simulate an obstruction.
The cylinder will remain in the obstruction
position while the doors attempt to close three

times.
After the third attempt, the cylinder in-strokes
to allow the doors to be fully closed.

Doors

Rails

Obstruction

Cylinder

The door testing system will require the following components


using Mitsubishi PLC :

1. Inputs to the PLC :


Start push button

X400

Stop push button

X401

Switch to open & close doors

X402

Left hand door sensor

X403

Right hand door sensor

X404

2. Outputs from the PLC :


Left hand door

Y430

Right hand door

Y431

Cylinder

Y432

Filling / Draining Control


Operation
Charge

and discharge of a reservoir is a

common process in industry as well as a need


for mixing two or more substances using
automated valves.

Consider

the charge and discharge system

displayed in figure, it is required to :


a) Operating the process in accordance to
the displayed operating panel.

b) Pressing (T1) on the operating panel, will


open valve (V1) to start filling up with
running the motor (M) until reaching (S1).

c) When completing filling up, valve (V1)


closes, motor stops and valve (V2) opens
to start emptying until reaching (S2) to

close (V2).
d) It is required that the reservoir has to be
filled up and emptied four times with the
same cycle before activating the Endlamp.

Automation of Parking Garage

Consider a simple system that can control 100


cars at the maximum.

Each

time a car enters, PLC automatically


adds it to a total sum of other cars found in
the garage.

Also,

each
car
that
comes
automatically be taken off.

out

will

When 100 cars park, a notifying signal that the


garage is full will turn on.

Otherwise a Vacancy signal should turn on.

SEQUENCE CONTROL PROCESS


Consider the motor movement control system
displayed in figure with the following features :
1. When the start button is pressed, the

motor will move from left to right.


2. When LS2 is on, the motor stops, delays for
5 sec. and then moves back to home.
3. When LS1 is on, motor cuts off signifying
that the sequence is completed

LS1

LS2
Stop

HOME

Start

Motor Right
Motor Left

Product Packaging
Consider the packaging system shown in figure
with the following features :
1. By pushing START key a Flag1 is activated.
2. Resetting depends only on a STOP key).

3. When started, motor of a conveyor for


boxes is activated. The conveyor takes a
box up to the limit switch, and a motor

stops then.

4. Starting the product conveyor is activated


by a limit switch when a box is detected.
5. The presence of a box allows counter to

count 10 products.
6. On activating the conveyor with boxes, a

limit switch resets counter to be ready to


count 10 products again.
7. Operations
pressed.

repeat

until

STOP

key

is

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