Final Year Presentation

Advisor : Akhtar Husain

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A programmable logic controller is a digital computer used for electromechanical processes.Unlike general purpose computers,the PLC is designed for multiple

IOs,extended temperature ranges,immunity to electrical noise and resistance to vibration and impact.A PLC is an example of real time system.Keeping in view the importance of PLCs,our project covers all the advanced applications of PLCs.

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PLC

applications

cut

across

discrete,process and hybrid automation segments and are poised for steady growth across all manufacturing.

Programmable Logic Controllers W.Bolton

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Advanced applications of PLCs

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AIM
To explore the advanced digital and analog applications of

PLCs with appropriate demonstration.

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Parts
Part I

Introduction
Abdul Wahab

Part II

Discrete application
Imran Khan

Part III

Analog application
Zahid Raza

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Introduction

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Introduction

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PLC Used
Allen Bradleys SLC 500 Belongs to Modular family Numerous power supply options Extensive I/O capacity Allows a system specifically designed for ones application Control hundreds of thousands of processes around the world Large choices of I/Os available from Rockwell Automation Can be upgraded to latest technology

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Development
Modern PLCs can be programmed in a variety of languages from ladder logic to more traditional languages such as Basic and C . We used Ladder Logic as programming language The reason of using Ladder Logic is that it allows the programmer to see any issues with the timing of the logic sequence more easily than other formats.

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Software Used
RS Logix 500 was used as the application software, the software allows entering and editing of Ladder style logic,and assists in debugging and troubleshooting the software. The sotware allows uploading and downloading of program between computer and PLC. Communication between computer and PLC was established through RS-232 The program is stored in battery backed-up-RAM.

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Functionality
Functionality have evolved over the years to include sequential relay control,process control,distributed control systems and networking. Data handling,processing power and communcation capabilities of some modern PLCs are approximately equivalent to some modern computers. The processor we used is Allen Bradleys SLC 5/03,1747-L531 Modular controllers of upto 4096 IOs and memory of 16k words can be configured using SLC 5/03

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5/03 provides bit instruction execution times of 0.44ms and overall system throughput of upto 10 times faster than competitive processors. Additional capabilities include floating point math,online programming , run time editing,flash memory upgrades , built-in key-switch , built-in real time clock and calender

Features
PLCs are armored for severe conditions and have extensive IOs as compared to other computers.

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Can read limit switches,analog process variables and position of complex positioning systems Some PLCs include machine vision.

System Scale
A small PLC has typical number of connections for IOs. Expansions are available if base model has insufficient IOs Several racks can be administrated by the single processor and may have thousands of IOs The PLC we are using has seven slots rack with following arrangements.

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I/O Configuration
# 0 1 Card Name 1747-L531 1746-IB16 Card Type 5/03,8k- Mem 16 input,24V(DC)

1746-0W16

16output(RLY),24 V(DC)
2 input, 2 Output(RLY) Analog 8 channel input-class 3 Analog 4 channel Voltage output

1746-IO4

4 5

1746-NI8 1746-NO4V

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RS Logix-500 features
A free-form ladder editor that lets concentrate on the application logic instead of syntax as we write our program A powerful project verifier that we can use to build a list of errors we can navigate to make corrections at convenience Drag-and-drop editing to quickly move data table elements from one data file to another, rungs from one subroutine or project to another, or instructions from rung to rung within a project An address wizard that makes entering addresses easier and reduces keying errors.

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RS Logix-500 features
Search and replace to quickly change occurrences of a particular address or symbol A point-and-click interface called a project tree that lets access all the folders and files contained in project A custom data monitor to view separate data elements together and observe interactions

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Communications
Communications settings are established using RS Linx software. We used RS-232 however RS-485 and ethernet are also available as communication protocols.

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Some initial work

Understanding RS-Logix 500 Completing all the exercises of Logix Pro Analyzing and fixing the faults of PLC trainer Adjusting the communication settings of Conveyor system which was not working before

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Discrete Application

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AIM
To make a mockup which utilizes the deep concepts of

digital control in PLCs with economic feasibility.

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Sorting system

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Function
In this application,the sorting system places the small

wooden blocks of three different sizes onto the conveyor after

specific interval of time and portions. seperates them into three

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Sorting System

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Mechanisms

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Process
Automatic Loading Detection Passing through Conveyor Sorting

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Process Diagram
Start

Action (Sorting)

Loading

Sorting System
Passing through Conveyor

(every 11secs)

Detection

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Process
Start

Loading

Detection

Processing

Sorting

Crank Shaft Mechanism

3-IR Sensors

Conveyor Belt

3-Spring loaded Plungers

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Pro E Model of the System

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Flash simulation

Similarly the third size is sorted The sensors are not indicated

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I/O Addresses
S.No
1 2 3 4 5 6 7

Type
Input Input Input Input Input Output Output Output

Component
Sensor 1 Sensor 2 Sensor 3 Red Switch Green Switch Conveyor motor Loader motor Green LED

Type of I/O
1746-IB16 1746-IB16 1746-IB16 1746-IB16 1746-IB16 1746-OW16 1746-OW16 1746-OW16

Address
I:1/3 I:1/4 I:1/5 I:1/1 I:1/0 O:2/6 O:2/0 O:2/1

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I/O Addresses
S.No
9

Type
Output

Component
Plunger 1

Type of I/O
1746-OW16

Address
O:2/7

10
11

Output
Output

Plunger 2
Plunger 3

1746-OW16
1746-OW16

O:2/3
O:2/2

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Sensor Circuits
Type
IR sensors were used

Designing Targets
To consider the sinking / sourcing of I/O cards To consider power requirements of I/O cards To achieve the appropriate range of detection

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Sensor Circuits
The sinking / sourcing of I/O cards
Sourcing output is required for sinking input card 1746IB16 We used PNP transistor BC-327 as a switch to produce the sourcing output

Power Requirements
The input card 1746-IB16 takes 22-24 V dc as logic 1,so we have to design the sensors accordingly

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Sensor Circuits

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Interface Circuit
Required to match the ratings of output components and PLC output card 1746 OW16 Consists of mechanical relays of 24V and 3A Input components like spring loaded plungers are having high current requirements which PLC cant fulfill,so seperate batteries have been used

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Connections from relays to Outputs

Relay No
1
2 3

Output
Plunger 1
Plunger 2 Plunger 3

4
5

Conveyor Motor
Loader Motor

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Programming
BSR,BSL
Instructions Bit Timers Counters
RES,CLR

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Description of Conditions and Actions

S.NO
1 2

Condition
Green button pressed Sensor 1 detects R6:0 enables T4:2 starts Sensor 2 detects

Action 1
Start conveyor BSL B3:0 shifts a bit to the left T4:1 starts for 7.5 Secs T4:2 starts for 1 sec BSL B3:1 shifts a bit to the left

Action 2
Start loader after every 11 secs R6:0 enables

3 4

With the DN bit of T4:1,T4:2 starts With the DN bit of T4:2,Plunger 1 strikes R6:1 enables

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Description of Conditions and Actions

S.NO 6 7 8 Condition R6:1 enables T4:4 starts Sensor 3 detects R6:2 enables T4:8 starts Action 1 T4:3 starts for 3 secs T4:4 starts for 1 sec BSL B3:2 shifts a bit to the the left T4:7 starts for 10.1 secs T4:8 stars for 1 sec Action 2 With the done bit of T4:3,T4:4 starts With the EN of T4:4,Plunger 2 strikes R6:2 enables

9 10

With the DN bit of T4:7,T4:8 starts With the EN of T4:8,Plunger 3 strikes

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Bit Shift Instruction

Bit Shift instruction

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Bit Shift Left

BSL

File address

Control address

Sensor Address

Length

The address of bit file in which to store array of bits

The address of control register whose bits are used to control operation

The address of the sensor which detects the presence of the object

The length of bit shift register to be used

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Process
When the rung goes from false to true the processor sets the enable bit (EN) and the data block is shifted to the left The specified bit at the bit address is shifted into the first bit position The last bit is shifted out of the array and stored in the unload bit The shift is completed immediately

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How BSL Works

Shift pulse is generated

The last bit is shifted out of array

BSL

Register checks if any object present

Indexing takes place to the left

If present,1 otherwise,0 is indexed into the register

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Advantages of Bit Shift Instructions Used

For tracking the status of blocks at any time by using the status window of Bit file used For determining how many blocks have been detected at any time By numbering the 1s in the register After how much time the blocks are loaded By numbering the number of 0s present betweeen 1s and then multiplying their number with the time of one bit shift The status of any bit position is tagged- can be used to perform the subsequent actions with reference to that tag

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How BSL Works

We used three BSL instructions for three separate sensors Now considering only one of them B3:0 for sensor #1 Shift Pulse is applied after every 2 seconds The first piston strikes after 6 seconds of detection
B3:0/7 0 0 0 0 0 0 0 B3:0/0 0

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How BSL Works

Considering that for the first shift pulse , object is detected,then
B3:0/7 0 0 0 0 0 0 0 B3:0/0 1

Considering that for the 2nd ,3rd and 4th shift pulses , no object is detected , then after 4th shift
B3:0/7 0 0 0 0 B3:0/3 1 0 0 B3:0/0 0

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How BSL Works

Besides using delays by timers , we used the delay of shift pulses by using the following logic : If B3:0/3 = 1 ,then output = 1 If B3:0/3 = 0 ,then output = 0
B3:0/7 0 0 0 0 1 0 0 B3:0/0 0

Sorting by the first piston after 6 seconds of detection

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Analog Application

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AIM
To implement the advanced advanced analog concepts of

PLCs

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Balancing Inverted Pendulum

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Why Pendulum ?
Available in the Robotics Lab Provides good practice for prospective control engineers Among the most difficult systems to control in the field of control engineering

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Hardware

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1746-NI8-Analog Input Card

8- differential channels

Hardware

Can be configured for voltage or current

Voltage range -10 to 10 volts Current range 0 20 mA
Fits into any slot except processor slot (0) in SLC 500

1746 NI8

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1746 NI8
Recieves and stores digitally converted analog data into its image table for retrieval Supports connections from any combination of upto eight voltage or current analog sensors Multi-class single slot module Class 1 utilizes 8 input and 8 output words class 3 configuration utilizes 16 input and 12 output words the 5/02 and higher processors can be configured for class 1 or class 3 We configured for class 3

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1746 NI8
The data presented to the processor can be configured as engineering units,scaled for PID,propotional counts (32768 to +32768 range),propotional counts with user defined range and1746-NI4 data format We used only scaled for PID and propotional counts data formats for configuration Provides open-circuit, out of range and invalid configuration indication via LEDs We used only two channels for inputs connected single endedly

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How NI8 Works

Input Signal

The processor and module determine that there is no error in transfer

A/D conversion

NI8
Mutilplexer sequentially switches each input channel

SLC processor reads converted data

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How NI8 Works

Memory map ( Class 3)
16 input words 8 data and 8 status 12-Ouput Channels-8 configuration words and 4 limit ranges

Input

Channel Data Word

1746-NI8

Channel Status Word

Configuration Word

SLC-500 Processor

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1746-NO4V-Analog Input Card

Hardware

1746 NO4V

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What we are doing is

Setpoint is applied from PLC ranging from -16383 to 16383 -10 to 10V +
Set Point

Servomotor
Control Output + +
Gain Potentiometer

Gain Potentiometer

Phase lead compensator

_ Y=X+L*z +
Gain Potentiometer

_ Control input we are Using as Process Variable +

Gain Potentiometer

Velocity Feedback Position Feedback(X)

Angle z

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I/Os Used
S.No 1746-NI8 1746-NO4V Used as

4.0

PV At the point indicated in the Previous slide SP At the point indicated in the previous slide Used as compensated output and applied at the point indicated

4.1

5.0

Controlled output

So what we did is that we replaced the phase lead compensator of the control console with the PID compensator using PLC

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How NI8 Works

From -16383 to 16383 -32767 to 32767
Scaling the output of PID Connecting I/Os

Config NI8 for PID

PID Implementation

Config. NI8 for propotional inputs Entering PID parameters

Scaling the input levels

From -32767 to 32767 -16383 to 16383