Discrete Control Logic

- Low forces
1. Pneumatic circuits
- Discrete, fixed travel distances
- Rotational or reciprocating motion
1 10
8 2
4 3
6
5
9

7
Supply Side

Usage Side
5

6
4
1
3 2

Main components: compressor, valves, cylinders

Pneumatic components: cylinders

double -acting

spring-return

• air supply

vent to atmosphere (air discharge)

tepping away from this mat, the person has to manually switch the robot back ON
Pneumatic components: valves

a 3/2 valve a 5/2 valve

valve actuation

return spring pneumatic

foot pedal push button

solenoid (electrical) roller (mechanical)

Simple Pneumatic control

START, A+, A-

- A +

A- A+ Start

•
VA
•

•
Pure Pneumatic control design: Cascade method

Example: Punch Press Operation:

(i) part is clamped in position

(ii) press punches the part
(iii) the clamp is released
(iv) part is removed from the table

START, A+, B+, B-, A-, C+, C-

Functions of A, B, C ?

How to design pneumatic system?

Pure Pneumatic control design: Cascade method

(1) Write cylinder action sequence

(2) Partition sequence into minimum no. of groups (no letter repeated in group)
(3) Merge last group, first group (if possible)
(4) Each cylinder is double-acting
(5) Each cylinder is controlled by 5/2 valve (both pilot lines: pneumatic)
(6) Each + and – position of cylinder: limit valves
(7) Each group => manifold line.
The manifold line connects to the limit valves associated with the cylinders.
(8) The air pressure in the manifolds is controlled by 5/2 valves called group valves.
no. of group valves = (no of groups – 1)
Cascade method: forming groups

START, A+, B+, B-, A-, C+, C-

Break it down into groups:

START, A+, B+ / B-, A-, C+ / C-

GRP 1 GRP 2 GRP 3

Merge Group 3 with Group 1 ?

START, A+, B+ / B-, A-, C+ / C-

GRP 1 GRP 2 GRP 1
Cascade method: draw cylinders, manifolds, valves

- Draw the cylinders

- For each cylinder, draw the limit valve (3/2 way)

- For each cylinder, draw the control valve

- Draw manifold lines

- Limit valve connections:

a2, b2 and c1 get their air supply from manifold 1

a1, b1 and c2 get their air supply from manifold 2

- Group valve connections:

air supply: initially to GRP 1 (manifold 1), when pilot line 1 is active.
line 1: activated by c2 (transition from GRP 2  GRP 1)
line 2: activated by b2

- Connect air supply of each cylinders valve, and supply + and – ports of each cylinder

- Connect the logic lines according to sequence: START  A+  B+  B-  A-  C+  C-

Cascade method: forming groups

- A + - B + - C +

a1 a2 b1 b2 c1 c2

- VA + - VB + - VC +
•

•
Start 1

1 2
•

Cascade circuit for: START, A+, B+, B-, A-, C+, C-

Pure Pneumatic Controls

- For more complex logic, difficult to debug

- Less versatile than electronic control (e.g. no counters, poor timer control)

- pneumatics timer control: delay valves.

Programmable Logic Controllers

History: avoiding complex/large relay boards

- Why are relay boards required?

6
ut
i np
u t5
inp
t4
PLC Basics: data communication wire u
inp
t3
s in pu

computer + relays O
ut
p ut

ut
1 i np
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2

in p
u t0
inp
C
A/ 0V
22

Box with
Computer
(controller)

Power supply wire

PLC: example 1

to PLC Output: 1
warning bulb robot

Sensor output,
connected to
PLC Input: 1

pressure sensitive mat

Pressure_Switch is ON Warning_Light ON

PLC: example 1

STEP 1:
Write this logic into a PROGRAM

STEP 2:
Load program into PLC

STEP 3:
Connect the sensor output to External Input terminal.

STEP 4:
Connect the PLC External Output Terminal to Warning Light

STEP 5:
EXECUTE the logic program on the PLC.
PLC: example 1

Programming language: LADDER LOGIC

I:0/1 O:0/1
PLC: example 1

Programming language: LADDER LOGIC

I:0/1 O:0/1

IF THEN
 to PLC Output: 1
PLC: example 2 warning bulb robot

Sensor output,
connected to
PLC Input: 1

Sensor output,
connected to
PLC Input: 2

inner pressure
sensitive mat

to PLC Output: 2
outer pressure
sensitive mat

Outer mat ON  warning light ON

Inner mat ON  warning light ON AND Robot OFF

Stepping away from inner mat  Manually switch robot ON

PLC: example 2

Two actuators: Warning light, Robot master switch

LOGIC for Warning light

External Input 1: outer mat

I:0/1 O:0/1

I:0/2

External Input 2: inner mat External output: light

PLC: example 2

I:0/1 O:0/1

LOGIC for Warning Light

I:0/2

I:0/2 O:0/2

LOGIC for Robot WRONG !

PROBLEM ?
 PLC: example 2

LOGIC for Robot

Robot must STAY OFF until manual reset to ON

Solution: LATCH

External Input 2: inner mat Internal (logical) relay

I:0/2 O:0/3
latch
Incomplete
O:0/3

O:0/3 O:0/2

External output: robot

PLC: example 2

LOGIC for Robot

Robot must STAY OFF until manual reset to ON

I:0/1 O:0/1

Legend:
I:0/2
I:0/1 connected to Outer Mat Switch

I:0/2 B1 I:0/2 connected to Inner Mat Switch

I:0/3

I:0/3 connected to Push Button for

B1 robot reset

O:0/1 connected to warning light

B1 I:0/2 O:0/2
O:0/2 connected to robot
Ladder Logic Programs

Switch (Relay) naming conventions

Lecture notes (Rockwell™ Automation PLC):

External inputs: I:0/1, I:0/2, …, I:1/1, I:1/2, … I:n/m
External outputs: O:0/1, O:0/2, …, O:1/1, O:1/2, … O:n/m
Internal Relays: B0, B1, …
etc.

Lab (SMC™ PLC):

External inputs: X0, X1, …
External outputs: Y0, Y1, …,
Internal Relays: R0, R1, …
etc.
PLC Example: XOR Logic

A xor B:

(A is ON AND B is OFF) OR (A is OFF AND B is ON)

Ladder Logic: Timers

Solenoid actuated door-lock Solenoid ON  Door unlocked

I:0/1 Solenoid actuated

T4: 1 when: O:0/1
(i) ON signal from number-pad outside door
(ii) ON signal from door-open switch inside door
Legend:
DN
I:0/2
Solenoid ON for 5 sec, then OFF I:0/1 Number Pad Signal to open door

O:0/1 I:0/2 Push Button signal to open door

O:0/1 Solenoid to unlock door

O:0/1
Timer: T4: 1
EN While O:0/1 remains ON,
DN
Base: 0.01 Timer COUNTS DOWN from PRESET
Preset: 500
Accum: 0 COUNT DOWN = 0  ( T4:1) set to ON
Ladder Logic: Timers
Solenoid actuated door-lock Solenoid ON  Door unlocked

Solenoid actuated when:

(i) ON signal from number-pad outside door
(ii) ON signal from door-open switch inside door

Solenoid ON for 5 sec, then OFF

I:0/1 T4: 1 O:0/1

DN Legend:
I:0/2
I:0/1 Number Pad Signal to open door

O:0/1 I:0/2 Push Button signal to open door

O:0/1 Solenoid to unlock door

O:0/1
Timer: T4: 1
EN

DN
Base: 0.01
Preset: 500
Accum: 0
 Ladder Logic: Timers -- reset

Solenoid actuated when: I:0/1 T4: 1 O:0/1

(i) ON signal from number pad outside door
(ii) ON signal from door-open switch inside door Leg
DN
I:0/2
Solenoid ON for 5 sec, then OFF
I:0/

During ON, if button is pressed, O:0/1 I:0/

Timer resets to PRESET
O:0
During ON, light indicator is ON O:0/1
Timer: T4: 1
EN O:0
DN
Base: 0.01
Preset: 500
Accum: 0

LEGEND: O:0/1 O:0/2

I:0/1  door-open
I:O/2  card-reader

I:0/2 T4: 1
O:0/1  solenoid
O:0/2  light indicator RESET
Ladder Logic: counters

Count the number of occurrences of an event

Examples:

Pallet loading in factory

After 10 parts arrive on conveyor, worker comes to load pallet

Pneumatic press hammer

Hit the part 20 times, then wait for part to be unloaded

Rice cooker alarm

Beep 5 times when rice is cooked

EVENT: switch goes from OFF  ON

Ladder Logic: counters
Pallet loading in factory After 4 parts arrive on conveyor:

STOP conveyor belt

turn ON the indicator light

I:0/1
Legend:
Count Up
CU
Counter: C5: 1 I:0/0 Conveyor ON
DN
I:0/1 Photo switch
Preset: 4
Accum: 0 I:0/2 Operator controlled Push
Button to restart conveyor
C5:1 O:0/2

DN
O:0/1 Conveyor belt
O:0/2 O:0/1
I:0/0
O:0/2 Light Indicator

I:0/2 C5: 1
RESET
Ladder Logic: car wash

Car arrives  limit switch ON

Limit switch ON  Washer ON

Washer ON:
(i) Soapy water SPRAY ON (30 secs)
(ii) Rinse: clean water SPRAY ON (30 secs)
(iii) Automatic scrubber brushes car (15 secs)
(iv) After washing 50 cars, the scrubber brush Auto-change
I:0/1 I:0/2 B1

B1
T4: 0
I:0/1 : System On
EN
Base: 0 .01 I:0/2 : Em ergency Stop
Preset: 3000
I:0/3 : Limit Switch
Accum : 0
B1
O:0/0 : Soap Water On
T4: 1
O:0/1 : Rinse On
EN
Base : 0.01 O:0/2 : Scrubber On
Pre set: 6000
O:0/3 : Activate Scrubber Change
Accum : 0
B1
Notice how B1 and the timer outputs are
T4: 2
used to control the logic
EN
according to the required timing.
Base: 0.01
Pre set: 7 500
Accum : 0

B1 T4:0 T4:1 T4:2 O:0/0

DN DN DN
B1 T4:0 T4:1 T4:2 O:0/1

DN DN DN
B1 T4:0 T4:1 T4:2 O:0/2

DN DN DN
O:0/2
CTU C5 : 0
EN
Preset: 50
Car arrives  limit switch ON
Accum : 0

C5 : 0 O:0/3 Limit switch ON  Washer ON

DN
I:0/3 T4 :0
Washer ON:
RES (i) Soapy water SPRAY ON (30 secs)
I:0/3 T4 :1
(ii) Rinse: clean water SPRAY ON (30 secs)
RES (iii) Automatic scrubber brushes car (15 secs)
I:0/3 T4 :2
(iv) After washing 50 cars, the scrubber brush Auto-change
RES

O:0/3 C5:0
RES
Programming a PLC

(1) Hand held console (direct feed of program into PLC)

(2) Computer-interface:
(i) Complete the program on a computer
(ii) Test the program on PC
(iii) Upload the program to the PLC processor memory (persistent)
(iv) Connect external Inputs and Outputs
(v) Run the program on PLC
Operation cycle of PLC
Phase 2
Phase 1
Phase 3

00 00

01
Program
30 30
02 Memory

03 31

04 32

05 33
Processor
06 34

07 35
08 36
Accumulator
09
37 37
10
output output
11 11 register

input input
register