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INDUSTRIAL
AUTOMATION
Lecturer: Nguyen Duc Hoang

Department of Control & Automation

Faculty of Electrical & Electronics Engineering
Ho Chi Minh City University of Technology
Email: ndhoang@hcmut.edu.vn

Chapter 4:
PLC Ladder Diagrams for Sequencing Systems
Commonly used industrial

sequencing control system

Sequencing chart

Cascade

method

Examples

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Commonly used industrial sequencing

control system
Sequencing control system: single path or multi-path systems.
Multi-path or parallel path sequencing control system: multi-tasks
Single-path sequencing system : one task.

Commonly used industrial sequencing

control system
Single-path sequencing system

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Commonly used industrial sequencing

control system
Multi-path sequencing system

Commonly used industrial sequencing

control system
Multi-path sequencing system with two or more alternative path selection

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Commonly used industrial sequencing

control system
Multi-path sequencing system with option bypass machine sequence

Commonly used industrial sequencing

control system
Multi-path sequencing system with option repeat certain steps

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Sequencing chart
Sequence charts (also called time-motion diagrams, state diagram,
or bar charts) are useful for visualizing the operation of switching
systems.
They can be used to describe the step-by-step operation of relay
systems, pneumatic systems, or any other type of switching systems.

Sequencing chart
Example: Control two double acting cylinders using 5/2 solenoid
valve with return spring and two limit switches.
Sequence: START, A+,A-,B+,B-

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Sequencing chart
Example: (cont.) START, A+,A-,B+,B-

Design Ladder Logic for Sequencing

Problems using PLCs
Three different methods for designing :
Sequencing

charts

Cascade
Huffman

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Cascade method
The various steps of the sequence are divided into groups according to
the following rule:
a new group must be started the moment it becomes necessary to shut
off any output signal actuated during the presently active group.
In other words, any output signal is permitted to remain actuated as
long as the group it belongs to remains active

Cascade method
Single Path Sequencing Systems without Sustained Outputs
Example: consider the given machine sequence having 3 pneumatic
double acting cylinders and having a machine cycle given as follows
START, A+, A-, B+, C+, B-, C-.

X cylinder, is actuated using a 5/3

directional valve having two
solenoids, X+ and X-, respectively,
with two return spring to provide
the middle position of the
directional valve.

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Cascade method
Single Path Sequencing Systems without Sustained Outputs
Example: (cont.) sequence can be divided into three groups such
that no letter is repeated in any group and given as follows

Cascade method
Single Path Sequencing Systems without Sustained Outputs
Example: (cont.)

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Cascade method
Single Path Sequencing Systems with Sustained Outputs
Example: control sequence of 3 cylinders with 5/2 ways directional
valve with spring return and having a machine cycle given as follows
START, A+, A-, B+, C+, B-, C-.

Cascade method
Single Path Sequencing Systems with Sustained Outputs
Example: (cont.)

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Cascade method
Single Path Sequencing Systems
Practice: control sequence of 4 cylinders as follows and simulate using
Unity Pro
START, A+, B+, C+, C-, A-, D+, A+, D-, B-, A-

(using cylinder actuating valves with a return spring)

Cascade method
Multi Path Sequencing Systems

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Cascade method
Multi Path Sequencing Systems
Example: control sequence with two parallel paths

The machine sequence can be grouped as follows:

Cascade method
Multi Path Sequencing Systems
Example: (cont.)

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Cascade method
Multi Path Sequencing Systems
with option repeat certain steps

Cascade method
Multi Path Sequencing Systems with option repeat certain steps
Example: control sequence with option repeat certain steps

The machine sequence can be grouped as follows:

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Cascade method
Multi Path Sequencing Systems
with option repeat certain steps

PRACTICE PROBLEMS

A master switch is used to start the

process and to shut it down. Two sensors:
an upper limit switch that indicates when
the piston is fully retracted and a lower
limit switch that indicates when the piston
is fully extended. When the master switch
is turned on the piston reciprocates
between the extended and retracted
positions. This is achieved with an up and
down solenoid. When the master switch is
turned off, the piston returns to the
retracted position and all solenoids are off.

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PRACTICE PROBLEMS
Bottle-filling system

PROBLEMS: Elevator system

1. When the START (NO) button is pushed,
the platform is driven to the down position.
2. When the STOP (NO) button is pushed,
the platform is halted at whatever position it
occupies at that time.
3. When the UP (NO) button is pushed, the
platform, if it is not in downward motion, is
driven to the up position.
4. When the DOWN (NO) button is pushed,
the platform, if it is not in upward motion, is
driven to the down position.

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PROBLEMS: Drilling system

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