STATE DIAGRAM EXERCISES

Problem 1

In a manufacturing cell we find two conveyors, a robot, and a pallet as shown in the
figure. The PLC controls the system as follows:

• Pressing a START button the process begins.

• Conveyor 1, activated after pressing the START button, brings boxes. The
proximity sensor detects a box and the PLC stops the conveyor.
• The PLC activates the robot through a signal ROBOT_PLC.
• The robot moves the box to the pallet and return a signal ROBOT_OK to the PLC
when finishes.
• The process will repeat until 4 boxes have been placed in the pallet. Then, the
PLC activates conveyor 2 for 5 seconds in order to take the pallet out.
• After that, the system goes back to the idle state.

PLC
Signal ROBOT_OK START button

Robot (ROBOT_PLC)

Pallet
Proximity
Sensor

Conveyor 2
Conveyor 1

Assignment:
• Make a list of I/O.
• Draw and explain the STATE DIAGRAM that models the system.
• Program the system using LADDER LOGIC.
Problem 2

Consider an automatic system used for loading fruit boxes. It is based on two
conveyors, as shown in the figure:

When the START button is pressed the boxes conveyor moves (BC) until a new
empty box is placed in the filling position detected by the “box sensor” (BS).
Once the box is in the filling position, the fruit conveyor (FC) moves and the fruits
start falling inside the box. Each box must be filled with 12 fruits, each one
detected by the fruit sensor (FS) situated at the edge of the conveyor as shown in
the figure.
When the box is full, the fruit conveyor stops and the box conveyor moves in order
to take the full box out and situate a new empty box at the filling position.

If the STOP button is pressed, the system will stop inmediately returning to the
initial state. If a box is at the middle of the filling process, it must be manually taken
before the process begin again.

Note: After the 12th fruit is detected, wait 1 second before moving the box conveyor
in order to let it fall inside the box.

Assignment:
• Make a list of I/O.
• Draw and explain the STATE DIAGRAM that models the system.
• Program the system using LADDER LOGIC.
Problem 3

Let's consider a coffee machine that works as Explained below:

1) The client selects whether he wants his coffee with sugar (A button) or
without sugar (B button).
2) When He presses one of the buttons (A or B) the machine starts working in
the following way:
a) If the client has chosen the “sugar option” (button A) the glass is
positioned at the right place (the action takes 2 seconds) and afterwards
the sugar is dropped for 5 seconds.
b) If the client has chosen the “no sugar option” (button B) the glass is
positioned (for 2 seconds).
c) After the previous stages (a or b) have been completed coffee and milk
are poured simultaneously (coffee for 5 seconds and milk for 10
seconds).
d) After coffee and milk are poured the machine returns to the initial state.

There are no sensors in the system. If the machine runs out of milk, coffee or
glasses, the errors are not managed by the system. The case of there being already
a positioned glass at the beginning of the process is not considered either.

Assignment:
• Make a list of I/O.
• Draw and explain the STATE DIAGRAM that models the system.
• Program the system using LADDER LOGIC.
Problem 4

We would like to automate a stamping machine working as follows:

When the user presses the advance button (A1), a part is heated activating
resistance (R) during 10 seconds. After that, a conveyor belt (CA) moves the part
onto the stamping base. Sensor A3 detects when the part is in position.
Once the object is at the stamping position, a piston with the stamping matrix (BE)
moves down, impacting with the part surface and moving back up (SE). Then, the
conveyor belt moves the part back to the initial position (RC) where it stays there
for 10 seconds to heat the part again. Sensors A2 and A6 detect when a part is at
the initial and final position, respectively. Sensors A4 and A5 indicate the position
of the stamping piston. That is, A4 detects that the piston is at the lowest position,
and A4 detects that the piston is at the upper position.
The stamping process is repeated three times. After the last one, instead of moving
to the initial position, the part advances to the final one. Simultaneously, while the
part is moving towards the final position, the system activates an audio signal (SA)
to notify the operators that the process has finished.
While the whole process is running, red light is on (LR). This light switches off 5
seconds after the part is at the end of the belt (final position).

Forward
Backward

Assignment:
• Make a list of I/O.
• Draw and explain the STATE DIAGRAM that models the system.
• Program the system using LADDER LOGIC.
Problem 5

CAN CLOSING SYSTEM

We want to automatize the operation of a can closing system that works as follows:

• Button S0 activates the conveyor belt that moves cans. Once a can arrives at
the position of sensor S10, the belt stops and the piston that holds the lid
moves. After the lid is in position, the piston moves back. Sensors S2 and S1
signal the final and initial position of the piston, respectively.

• Then, the belt moves to the position given by sensor S5. A tool (K3)
activates to close the can. S4 indicates that the tool has finished and then
the belt moves again to place the can in a box (detected by S6).

• When 4 cans have been placed in the box, the system activates a light (L)
that indicates that the box is full. The process stops then until an operator
moves the box out, replaces it and presses the S0 button to continue the
operation.

Assignment:
• Make a list of I/O.
• Draw and explain the STATE DIAGRAM that models the system.
• Program the system using LADDER LOGIC.
Problem 6
Automatized Riveting Machine

We are to design a machine for joining two sheets of metal with 5 rivets. The sheets are
fixed, and the riveting machine can move between the holes in which the rivets are to be
placed (assume the holes already exist). When the process has completed (a series of 5
rivets), the machine returns to the initial position to be ready for a new series. See figure
below (rivet holes not shown).

The system has a sensor S1 that is used to detect when the machine is in the initial
position. This position also corresponds to the position where the first hole is to be
riveted. The motor that drives the belt on which the riveting machine is fixed is a stepper
motor and every 120th pulse (sent to this motor) positions the riveting machine above a
hole to be riveted. The output M1L moves the riveting machine left (as when moving from
the initial position in the figure), while M1R indicates right.

The motor M2 is of a continuous current type (not a stepper motor). This motor begins
operating when the start button is pressed (On) and is active every time a rivet is to be
made but is deactivated whenever the riveting machine is moving. You can assume the
riveting operation only requires the activation of this motor, and that the end of a riveting
operation can be detected by sensor S2. More specifically, a riveting operation has ended
when a rising edge (change from low to high logical state) occurs in sensor S2. This event
signals that the riveting machine has returned to its upper position, and that a movement
with motor M1 is once again possible.

Notes:
• Motor M1 send a signal per each pulse (S_M1).
• The activation of the riveter involves the movement of descent and rise.

Assignment:
• Make a list of I/O.
• Draw and explain the STATE DIAGRAM that models the system.
• Program the system using LADDER LOGIC.
Problem 7

LABEL DETECTION SYSTEM

Consider the label detection system of a bottling machine as shown in the figure.
The process evolves as follows:

The process begins when the start button (BA) is pressed. Then, the CTA conveyor
belt starts to move. Bottles are placed on this tape. If the photoelectric cell (CF)
detects a defective bottle, that is, it has no label, the CTB conveyor belt begins to
move. When the bottle reaches the P position: the CTA belt is stopped, the
manipulator (MA) takes the bottle and leaves it on the CTB conveyor. The CTB tape
continues to move for 10 seconds after the manipulator has returned to its initial
position. After this time, CTB stops and CTA begins to move repeating the process.
When the 5 defective bottles is reached, an alarm light (LA) should be turned on
and the 10th, the process should be stopped by returning to the state from which it
is started (before pressing the start button).

Notes:
• Consider that the photoelectric cell (CF) is activated when it detects a tag.
• Each time the manipulator finishes its program (takes a bottle, places it in CTB
and returns to CTA), it sends a signal to the PLC (MA-PLC).

Assignment:
• list the Inputs and Outputs of the system (I/O).
• Draw and explain the STATE DIAGRAM that models the system.
• Program the system using LADDER LOGIC.
Problem 8

GARAGE DOOR

A garage door works as follows:

• When a car approaches, it is detected by an ultrasound sensor (US). At that

very moment, the door begins to open (MOp) until the limit switch (LSO)
detects it is completely open.
• The door remains open for 20 seconds. After that, the door begins to close if
and only if the photosensor PS detects there is no car, or any other obstacle,
in the middle. If there is an obstacle, the door remains wide open until the
photosensor indicates that nothing is in the middle.
• If the door is closing and another car is detected (either by US –approaching
- or by PS - passing) the door will open wide again.
• The system can work with no trouble for 100 cars. When 100 cars have
passed, it triggers a Rev signal, meaning the system needs to be checked.
• When the system has been checked, the technician presses button P. Until
that moment, the door must remain closed and blocked (detected by the
limit switch LSC) at the initial position.
• When the door is blocked (waiting for revision) a red light is on (RL). When
the door is closed but not blocked (normal functioning) a green light is on
(GL). In all other situations (opening, closing, or wide open) an orange light
is on (OL).

US

LSO

PS

LSC

Hint: The photosensor PS is activated when it does not detect an obstacle.

Assignment:
• Make a list of I/O.
• Draw and explain the STATE DIAGRAM that models the system.
• Program the system using LADDER LOGIC.
Problem 9

A SECURITY SYSTEM

Let us consider a system to control access to a building by password code. The

system has a 4-digit numeric keypad, namely: 1, 2, 3, 4. The operation is as follows:
if the sequence detected is: 1-2-1-3 the door latch opens for 5 seconds and the
system returns to its initial condition. In any other case/alternative sequence the
system does nothing. A maximum time of 3 seconds is considered as an interval
between two consecutive keys, if in that interval the following key is not pressed,
the system returns to rest.

A CANCEL key is available, to be pressed by the user at any time to make the
system return to its idle state.

Assignment:
• Make a list of I/O.
• Draw and explain the STATE DIAGRAM that models the system.
• Program the system using LADDER LOGIC.
Problem 10

Can filling station

Design and program an automatic can filling system according to the following
instructions:
A conveyor activated by a motor (CM) transports the cans.
The filling area allows the selection of products A or B thanks to a simple effect
cylinder C that changes the position of the valves.
When sensor (S1) detects a can in the filling area the conveyor stops:
• If the selection is product A, valve VA would open for 5 seconds.
• If the selection is B, the valves would be moved to position by pushing the
cylinder to its limit position (limit switch LSC). Then valve VB would open for 6
seconds and after that the cylinder would be taken back to the A position.

Once the can is full, the conveyor moves again until the can reaches the capping
area (sensor S2). A signal CAP would ask the capping machine to place the cap, and
it will send signal CAPEND once the cap is in place. Then, the process may
continue.
According to production needs, the system will fill series of 5 cans, 4 with product
A and one with product B.
The production of each series requires one push of button START.

CAPPING
MACHINE

Assignment:
• Make a list of I/O.
• Draw and explain the STATE DIAGRAM that models the system.
• Program the system using LADDER LOGIC.
Problem 11

BOTTLE WASHING

Consider a system for cleaning bottles. The system works as follows:

• There is a belt which is moving since the moment the system is started. The
belt never stops. The system is started using a button B. The belt is
activated with the signal BELT.

• The bottles are placed on the belt by an operator. Nothing can be assumed
about the positioning of the bottles.

• Sensor S detects the arrival of a bottle to the washing area. A passive

retention device stops the bottles at the end of the washing area, so they
cannot go on (even if the belt is still moving).

• When 6 bottles have arrived to the washing area (each time a bottle arrives
sensor S triggers a signal) a retention device at the entrance of this area is
activated with the output RD so no more bottles come in.

• Washing proceeds: valve V opens for 5 seconds to let the water come out
and wash the bottles. Then a motor M is activated in order to turn the
bottles upside down and empty them. This process is repeated twice.

• When the cleaning process is finished a simple effect cylinder is activated

(signal C) placing the bottles on their delivery position. When the cylinder
has reached its end position (bottles in place) signal CEND activates. The
cylinder is then released (returns by spring). When the cylinder has
reached its initial position CINT activates.

• Afterwards the retention device is released and the process continues.

Assignment:
• Make a list of I/O.
• Draw and explain the STATE DIAGRAM that models the system.
• Program the system using LADDER LOGIC.