Discrete Control Logic

- Low forces
1. Pneumatic circuits
- Discrete, fixed travel distances
- Rotational or reciprocating motion

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?

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Box with
Computer
(controller)

Power supply wire

PLC: example 1

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

PLC: example 1

Programming language: LADDER LOGIC

IF THEN
PLC: example 2

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

External Input 2: inner mat External output: light

PLC: example 2

LOGIC for Warning Light

LOGIC for Robot

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

latch

External output: robot

PLC: example 2

LOGIC for Robot

Robot must STAY OFF until manual reset to ON

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

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

While O:0/1 remains ON,

Timer COUNTS DOWN from PRESET

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

 Ladder Logic: Timers -- reset

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

During ON, if button is pressed,

Timer resets to PRESET

During ON, light indicator is ON

LEGEND:
I:0/1  door-open
I:O/2  card-reader

O:0/1  solenoid
O:0/2  light indicator
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
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 : Emergency Stop
Preset: 3000
I:0/3 : Limit Switch
Accum : 0
B1
O:0/0 : Soa p Water On
T4: 1
O:0/1 : Rinse On
EN
Base: 0.01 O:0/2 : Scrubber On
Preset: 6000
O:0/3 : Ac tivate Scrubber Change
Accum : 0
B1
Notice how B1 and the time r outputs are
T4: 2
used to c ontrol the logic
EN
according to the required timing.
Base: 0.01
Preset: 7500
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:
Car arrives  limit switch ON
50
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