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UNIVERSITY OF GONDAR

INSTITUTE OF TECHNOLOGY
ELECTRICAL AND COMPUTER ENGINEERING DEPARTMENT
ECEg4332: INDUSTRIAL AUTOMATION
WORKSHEET I

1. Write the Boolean expression and draw the gate logic diagram and typical PLC ladder logic
diagram for a control system wherein a fan is to run only when all of the following conditions are
met:
Input A is OFF
Input B is ON or input C is ON, or both B and C are ON
Inputs D and E are both ON
One or more of inputs F, G, or H are ON
2. Write the ladder logic program needed to implement each of the following (assume inputs A, B,
and C are all normally open toggle switches):
When input A is closed, turn ON and hold ON outputs X and Y until A opens.
When input A is closed and either input B or C is open, turn ON output Y ;
otherwise, it should be OFF.
When input A is closed or open, turn ON output Y.
When input A is closed, turn ON output X and turn OFF output Y
3. Express each of the following equations as a ladder logic program:
Y =(A + B)CD
C+ D+
Y=A B E

Y =[ ( A+
B ) C ] + DE

BC
Y =( A ) + ( D E F )

4. It is required to have a pilot light come on when all of the following circuit requirements are
met:
All four circuit pressure switches must be closed.
At least two out of three circuit limit switches must be closed.
The reset switch must not be closed.
Using AND, OR, and NOT gates, design a logic circuit that will solve this hypothetical problem.
5. What instruction would you select for each of the following discrete input field devices to
accomplish the desired task? (State the reason for your answer.)
Turn on a light when a conveyor motor is running in reverse. The input field device
is a set of contacts on the conveyor start relay that close when the motor is running
forward and open when it is running in reverse.
When a pushbutton is pressed, it operates a solenoid. The input field device is a
normally open pushbutton.
Stop a motor from running when a pushbutton is pressed. The input field device is a
normally closed pushbutton.
When a limit switch is closed, it triggers an instruction ON. The input field device is
a limit switch that stores a 1 in a data table bit when closed.

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UNIVERSITY OF GONDAR
INSTITUTE OF TECHNOLOGY
ELECTRICAL AND COMPUTER ENGINEERING DEPARTMENT
ECEg4332: INDUSTRIAL AUTOMATION
WORKSHEET I

6. The process shown in the following Figure is to be used to


control the level of water in a storage tank by turning a
discharge pump on or off. Develop PLC program in
automatic mode of operations are as follows:
If the level of water in the tank reaches a high
point, the water pump will start so that water
can be removed from the tank, thus lowering
the level.
When the water level reaches a low point, the
pump will stop.
Turning on the following indicators
- Water pump running (green)
- Low water level status light (red)
- High water level status light
(yellow)

7. Develop a ladder diagram for the simple sequential


process with reference to the process flow diagram
illustrated in Figure . The sequential task is as follows:
Start button is pressed.
Table motor is started.
Package moves to the position of the limit
switch and automatically stops.
A stop button that will stop the table, for any
reason, before the package reaches the limit
switch position
A red pilot light to indicate the table is stopped
A green pilot light to indicate the table is running

8. Figure shows the sketch of a drilling process that requires the


drill press to turn on only if there is a part present and the
operator has one hand on each of the start switches. This
precaution will ensure that the operators hands are not in the way of the drill. The sequence of
operation requires that switches 1 and 2 and the part sensor all be activated to make the drill motor
operate. Develop an ladder program to operate the motor.

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UNIVERSITY OF GONDAR
INSTITUTE OF TECHNOLOGY
ELECTRICAL AND COMPUTER ENGINEERING DEPARTMENT
ECEg4332: INDUSTRIAL AUTOMATION
WORKSHEET I

9. A temperature control system consists of four thermostats controlling three heating units. The
thermostat contacts are set to close at 50, 60, 70, and 80F, respectively. The PLC ladder logic
program is to be designed so that at a temperature below 50F, three heaters are to be ON. Between
50 to 60F, two heaters are to be ON. For 60 to 70F, one heater is to be ON. Above 80F, there is
a safety shutoff for all three heaters in case one stays on because of a malfunction. A master switch
is to be used to turn the system ON and OFF. Prepare a typical PLC program for this control
process.

10. A pump is to be used to fill two storage tanks. The pump is manually started by the operator
from a start/stop station. When the first tank is full, the control logic must be able to automatically
stop flow to the first tank and direct flow to the second tank through the use of sensors and electric
solenoid valves. When the second tank is full, the pump must shut down automatically. Indicator
lamps are to be included to signal when each tank is full.
a. Draw a sketch of the process.
b. Prepare a typical PLC program for this control process.

11. Figure shows the sketch of a continuous filling operation.


This process requires that boxes moving on a conveyor be
automatically positioned and filled. The sequence of operation
for the continuous filling operation is as follows:
Start the conveyor when the start button is momentarily
pressed.
Stop the conveyor when the stop button is momentarily
pressed.
Energize the run status light when the process is operating.
Energize the standby status light when the process is stopped.
Stop the conveyor when the right edge of the box is first
sensed by the photo sensor.
With the box in position and the conveyor stopped, open the solenoid valve and allow the box to
fill. Filling should stop when the level sensor goes true.
Energize the full light when the box is full. The full light should remain energized until the box is
moved clear of the photo sensor.

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UNIVERSITY OF GONDAR
INSTITUTE OF TECHNOLOGY
ELECTRICAL AND COMPUTER ENGINEERING DEPARTMENT
ECEg4332: INDUSTRIAL AUTOMATION
WORKSHEET I

12. A motorized overhead garage door is to be operated automatically to preset open and closed
positions. The field devices include one of each of the following:
Reversing motor contactor for the up and down directions.
Normally closed down limit switch to sense when the door is fully closed.
Normally closed up limit switch to sense when the door is fully opened.
Normally open door up button for the up direction.
Normally open door down button for the down direction.
Normally closed door stop button for stopping the door.
Red door ajar light to signal when the door is partially open.
Green door open light to signal when the door is fully open.
Yellow door closed light to signal when the door is fully closed.
The sequence of operation requires that:
When the up button is pushed, the up motor contactor energizes and the door travels upward until
the up limit switch is actuated.
When the down button is pushed, the down motor contactor energizes and the door travels down
until the down limit switch is actuated.
When the stop button is pushed, the motor stops. The motor must be stopped before it can change
direction.

13. Write the optimum ladder logic rung for each of the following scenarios, and arrange the
instructions
for optimum performance:
a. If limit switches LS1 or LS2 or LS3 are on, or if LS5 and LS7 are on, turn on; otherwise, turn
off. (Commonly, if LS5 and LS7 are on, the other conditions rarely occur.)
b. Turn on an output when switches SW6, SW7, and SW8 are all on, or when SW55 is on. (SW55
is an indication of an alarm state, so it is rarely on; SW7 is on most often, then SW8, then SW6.)

14. In this industrial application, there is a machine with a large steel shaft supported by babbitted
bearings. This shaft is coupled to a large electric motor. The bearings need lubrication, which is
supplied by an oil pump driven by a small electric motor. The operation of the program can be
summarized as follows:
To start the machine, the operator turns SW on.
Before the motor shaft starts to turn, the bearings are supplied with oil by thepump for 10
seconds.
The bearings also receive oil when the machine is running.
When the operator turns SW off to stop the machine, the oil pump continues to supply oil for
15 seconds.
A retentive timer is used to track the total running time of the pump. When the total running time
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UNIVERSITY OF GONDAR
INSTITUTE OF TECHNOLOGY
ELECTRICAL AND COMPUTER ENGINEERING DEPARTMENT
ECEg4332: INDUSTRIAL AUTOMATION
WORKSHEET I

is 3 hours, the motor is shut down and a pilot light is turned on to indicate that the f lter and oil
need to be changed.
A reset button is provided to reset the process after the filter and oil have been changed.

15. Write a program to implement the process illustrated in Figure. The


sequence of operation is to be as follows:
Normally open start and normally closed stop pushbuttons are used to start
and stop the process.
When the start button is pressed, solenoid A energizes to start filling the
tank.
As the tank fills, the empty level sensor switch closes.
When the tank is full, the full level sensor switch closes. Solenoid A is de-
energized.
The agitate motor starts automatically and runs for 3 min to mix the liquid.
When the agitate motor stops, solenoid B is energized to empty the tank.
When the tank is completely empty, the empty sensor switch opens to de-energize solenoid B.
The start button is pressed to repeat the sequence
16. In this process, conveyor M1 is used to stack metal plates onto conveyor M2. The photoelectric
sensor provides an input pulse to the PLC counter each time a metal plate drops from conveyor M1

to M2. When 15 plates have been stacked, conveyor M2 is activated for 5 s by the PLC timer.

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