Faculty: FACULTY OF ENGINEERING

rd
Subject : Specialized 3 Year Review : 0
Laboratory (PBL) Released date : 1 February 2018
Amendment : -
Subject code : SKEE/SKEM/SKEL 3742 Procedure no. : MI-UTM-FKE-(1)-10

SKEE/SKEM/SKEL 3742

SCHOOL OF ELECTRICAL ENGINEERING

UNIVERSITI TEKNOLOGI MALAYSIA
SKUDAI CAMPUS
JOHOR

APPLIED CONTROL LABORATORY

STUDENT PACK
Introduction to PLC and Design (Using GLOFA GM6 PLC)
Factory Automation System (ED-4031) – Task 1

Prepared by : Dr. Sophan Wahyudi Nawawi Approved by : DIRECTOR

Name :Dr Herman Wahid Name : Assoc. Prof. Ir. Dr. Norhaliza
Dr. Nurul Adilla Mohd Subha Abdul Wahab
Hj. Mohamad Shukri
Abdul Manaf
Signature : Signature :

Stamp : Stamp :

Date : 1 February 2018 Date : 1 February 2018

1. Problem/Project Guide:

Programmable Logic Controller (PLC) is a highly autonomic program controller that replaces the existing relay, timer
and counter functions with semiconductor elements. It is like integrated circuit (IC) and transistor with a numeric
operation function to basic sequence control function. According to the National Electrical Manufacturers
Associations (NEMA), PLC defined as “digitally working electronic device that uses a programmable memory and
controls various machines or processors to execute special functions like logic, sequencing, timing, counting and
operation through digital or analog input/output module”. In other words, PLC can be configured as an automation
system that performs an advanced control with various functions.

Prior to PLC, there are other similar devices that could configure the automation system based on mechanical logics
like hydraulic/pneumatic, electric relay sequence or hard-wired electronic logic circuit. Those devices include an
organic correlation between basic three control elements in a limited space and they play their own roles respectively
as follows:

1. Input: Represented by sensor, it converts physical signals into electric signal and send it to control element

2. Control: Receive information from sensor, judge it according to command conditions in a pre-set program and
send the processing results to the output element.

3. Output: Drive actual movement according to control signals displayed from control element by using actuator.

Information
detection Judgement/
/signal determination
transmission order
Physical
quantity Sensor Processor Actuator Operation
change reaching goal

Input Control Output

Figure 1: The correlations of the elements in the system

As it is easily programmable to accomplish a variety of control operations, it quickly gains wider applications in
industry by replacing its predecessor, the electromechanical relays. The relays are now commonly used as switches
and no longer as logical controllers. Logical systems are normally represented graphically by using state diagrams or
other similar methodologies. The representation is then transformed to ladder logic diagrams and implemented in PLC
by using its programming language which resembles the ladder logic diagram.

The purpose of this project is to control a factory automation system by using a PLC approach. The system includes
all the basic processes for production automation such as transfer, processing, inspection, classification and storage.

a) Problem Objectives:

 To design factory automation control system using GLOFA GM6 PLC and ED-4031 trainer.
 To demonstrate the proposed control sequence by using ladder diagram in GMWIN software.

b) Problem Design:

The PLC controller at your production line (which represented by ED-4031 system) is changed to the new one.
The sequential process is now controlled by GLOFA GM6 PLC system.

Your team is assigned to look into this problem and come out with a good solution to make sure the production
line can be operated as normal without any problem. The report for the solution needs to include the sequence of
operation for each check point in the production line system.
To tackle the problem design, students are required to perform the task in c section.

c) Task :

You need to perform the task under the following conditions. Please make sure the basic wiring is connected to
the system in accordance with the input & output wiring diagram, and write a PLC program to control the system,
and carry out its trial run.

1) Supply: Insert objects (all metal/nonmetal objects) into the magazine according to the conveyor system, as in
Figure 2. Press the Start Push button, the part sensor will detect the WORK. Then move forward the supply
cylinder to supply the WORK. After that move backward the supply cylinder by forward completion signal.
(Note: You also can used the object with hole to be considered as defected)
2) Processing: Press the Start Push button to move forward the drill working cylinder, process the WORK for
five (5) seconds and move backward the drill working cylinder.
3) Defective Extraction: Press the Start Push button to activate the conveyor belt and place the WORK on the
conveyor manually. If the WORK is judged as defective through the defective sensor, move forward the
extraction cylinder in three (3) seconds to extract the WORK.
4) Metal Extraction: Press the Start Push button to activate the conveyor belt and place the WORK on the
conveyor manually. If the WORK is judged as defective through the metal sensor, move forward the
extraction cylinder in three (3) seconds to extract the WORK.
5) Supply & Processing: Press the Start Push button, if the part sensor detects the WORK, move forward the
supply cylinder to supply the WORK and move forward the drill working cylinder to process the WORK for
three (3) seconds. Then move the backward the drill working cylinder to complete the processing and move
backward the supply cylinder to prepare transfer.
6) Transfer & Extraction: Press the Start Push button to operate the conveyor belt first. Then move forward the
transfer cylinder to transfer the WORK to the conveyor belt. Move backward the transfer cylinder and extract
the WORK with the extraction cylinder in five(5) seconds.
7) Transfer, Inspection & Extraction Task 1: Press the Start Push button to activate the conveyor belt first.
Then move forward the transfer cylinder to transfer the WORK to the conveyor belt. Move backward the
transfer cylinder and inspect the processing status by using the defective sensor. If it is judge as defective,
move forward the extraction cylinder in three (3) seconds to extract the WORK.
8) Transfer, Inspection & Extraction Task 2: Press the Start Push button to activate the conveyor belt first.
Then move forward the transfer cylinder to transfer the WORK to the conveyor belt. Then move backward
the transfer cylinder and inspect whether there is metal or nonmetal by using the metal sensor. If it is judge
the metal, move forward the extraction cylinder in three (3) seconds to extract the WORK. If it is judged as
non-metal, save the WORK into the good parts storage.
9) Supply, Processing, Transfer, Inspection & Extraction (Complete production line setup): Press the Start
Push button to activate the conveyor belt first. If the part sensor detects the WORK, move forward the supply
cylinder to supply the WORK and move forward the drill working cylinder to process the WORK for five (5)
seconds. Move backward the drill working cylinder to complete the processing. Then, move backward the
supply cylinder and move forward the transfer cylinder to transfer the WORK to the conveyor belt and move
backward the transfer cylinder. Inspect the transfer WORK by using the defective sensor/metal sensor. If it is
judge as defective, move forward the extraction cylinder in three (3) seconds to extract the WORK and stop
the conveyor. If it is judged as a nondefective, store the WORK into the good part storage and stop the
conveyor in ten (10) seconds.

Note: Please use the basic I/O allocation set to ED-4031 in Table 1. You may use suitable sensor S2 for defective
object detection.
 Figure 2: Conveyor system configuration diagram

A report supported with the experiment result is expected to be produced at the end of the task. The collected data
and analysis should be well presented and discussed in detail in the report.

d) Problem-solving Time-line

Activities Week 1 Week 2 Week 3

1. Briefing, PLC exercises, brainstorming,
oral interview, submission of proposal
2. Design/programming/experiments, oral
interview, individual report
3. Analysis, oral interview, demonstration of
final designed

e) Proposal write-up
You are expected to submit a handwritten project proposal on one page of paper + attachments (e.g. a
flowchart for software based project). Each write-up is to be submitted as teamwork on the first week of the
laboratory. Please ensure that each team member is responsible enough to contribute in completing the work.
Your proposal may include the following information:
 title
 objective
 problem statement
 methodology (flow chart/block diagram/list of equipment, materials)
 expected outcome

f) Report writing
A group report needs to be submitted in the post week after the third week of laboratory session. Your report
should follow the general guide by the Laboratory Coordinator such as abstract, introduction, methodologies
etc.

Other than the general guide, your report for this laboratory may also include:
 Review and circuit diagrams
 Data and graph as a results
 Photographs of the actual circuit construction
 Photographs of your group members

g) Questions That Can Help You Tackle The Problem
1) How does Factory Automation Trainer work?
2) What are the inputs and outputs of the system?
 3) How does the solenoid valve operated?
4) What is:
a. Timer
b. Counter
c. Single/ double acting cylinder
d. holding circuit
e. limit switch
f. capacitive/ inductive sensor
5) How do you define the accuracy of the design?

2. Equipment list:

(a) Factory Automation Trainer System ED-4031

(b) GLOFA GM6 PLC

3. Components list:

(a) Connector
(b) Jumper wire, wire
(c) Pneumatic air tubes

4. Software:

(a) PLC programming software: GMWIN Programmer

5 Additional resources:

Materials related to the problem/project. Can be technical papers, short manual on how to use GMWIN programmer
software or other software for a particular problem/project, links to websites etc. Examples as follows:
(a) GLOFA, 2001, “User Manual XG5000”.
(b) Factory Automation Trainer System ED-4031 – User manual
(c) Exercises of SMC pneumatic
(d) Please refer to page 2-24 (A Beginner’s Guide to PLC) to get examples of PLC electrical wiring.
(e) Figures of the Factory Automation Trainer System ED-4031 as follows:

Factory Automation Trainer System ED-4031 Conveyor System of ED-4031

 ED-4031 Panel Indicator (Unused) ED-4031 PLC Trainer Unit
(Unused I/O terminal as marked)

6. References:

Appendices

Figure 3: Basic wiring for ED-4031

Table 1: Basic I/O allocation set to the ED-4031

INPUT OUTPUT
%IX0.0.0 PB1 Start S/W %QX0.1.0
%IX0.0.1 LS1 Product supply %QX0.1.1 Y1 Product supply
cylinder backward cylinder forward
%IX0.0.2 LS2 Product supply %QX0.1.2 Y2 Product supply
cylinder forward cylinder backward
%IX0.0.3 LS3 Drill working %QX0.1.3 Y3 Drill working
supply cylinder supply cylinder
backward forward
%IX0.0.4 LS4 Drill working %QX0.1.4 Y4 Product transfer
supply cylinder cylinder forward
forward
%IX0.0.5 LS5 Product transfer %QX0.1.5 Y5 Defective
cylinder backward extraction
cylinder forward
%IX0.0.6 LS6 Product transfer %QX0.1.6 M2 Conveyor Belt
cylinder forward foward
%IX0.0.7 LS7 Defective %QX0.1.7
extraction
cylinder backward
%IX0.0.8 LS8 Defective %QX0.1.8 Y6 Defective
extraction extraction
cylinder forward cylinder 2
forward
%IX0.0.9 S1 Part Sensor %QX0.1.9 M1 Drill Rotation
motor
%IX0.0.10 S2 Defective Sensor %QX0.1.10 L1 Warning Light
1(green)
%IX0.0.11 S3 Material Arrival %QX0.1.11 L2 Warning Light
Sensor 2(yellow)
%IX0.0.12 S4 Metal Sensor %QX0.1.12 L3 Warning Light
3(red)
%IX0.0.13 LS9 Defective %QX0.1.13
extraction
cylinder 2
backward
%IX0.0.14 LS10 Defective %QX0.1.14
extraction
cylinder 2
forward
%IX0.0.15 PB2 Stop S/W %QX0.1.15