366 Soquel Aplications RODLEMS General instretions for the problems: Using the fineton cart apeooh, write lade ogi rogram forthe application Implement it for ae of te following PLC lade loi languages Modicon Concept, or Allen-Bradley PLC-S'SLC-S00, or ‘Allen-Bradley ContolLogix, oF ‘Siemens $7-300400, $7-200, GE Fanuc any part ofthe operation ambiguous, write don your atonal sumptions. ‘The physical inputs physica cups, nd ntl vara foreach problem are sven the problem. DO NOT ssign at more psa inputs! ‘You solution soul inci the following: | Function chart of the process showing the wansons Been psa the ‘outputs active (oon) during each stp. Specify he PLC processor used. Ladder loge diagram (ith comment), For consistency among te different PLCS, so only varablessymbolvtags inthe ladder loge Us intactons omit! withthe PLC processor abl listing addiona intemal memory variblesymbolsags) used and a lef desertion oftheir use. Fr the Alln-Bradley ConolLogt and the Modicen Canep processor st the trl varialestogs end the dat ps Forthe ther presses isthe otra varislessymale a he soca memory aes, Note to instr: Break each problem into wo assignments. Forth is assignment, the suds draw the function chart The second assignment pln the lade lagi Forthesecondasigament, the stents rllowod owe the come ncn cho tei function chart it x let the correct soliton. This appeach wil sive the rsrctor from nein o grade many feet lade logic oltons. 6-1.Canon Scaler Coal. Iplemet th prora forth following tition tha sand seals comugated eardoard bo, Figure Pt shows two views ofa ton ta olds and gles comugated caritoard box. Assume the open bores ae already illd with product Upon Staup be conveyor motors om ul the photoeletrc eye sense ox ithe station. When aot sin the station te conyers stopped th box closed ‘nscale bythe flowing procedure Twa pacuatcrams(FRONT and BACK) !neextndod to push the two end Maps down 9 pie sprayer is stat fT ‘Scopd, and then two mre poeumatie rams (CEPT and RIGHT) ae extend to push he wo sie lps down, Alera sosond wall ofthe puma rasaPROBLEMS 367 Front Ranh Back Ran Om comer Left Rem igh Rar PEL seas the Frat ee o- Or © Figure Pt Box sealing station; view fom It sie; (view fom font. ‘erated andthe conveyor mortar on. The eed box ismoved ou the ation andthe conveyor cotiues to ran al ape box moves nto the sation, ‘Thus the operation repeats. Assue thre ap between he bones 0 hat I Phoostesri eye wil also sense that here sma box ia he ston afer he sealed tor femoved eu, Esch rum ss sngle-action liner pcumaticcpindr controlled by one ‘supa Ones ouput enetgaed,the ram exten a Keoe moving song ower is applied (med on) or a mechanical sop is cached. The ram rect. when powers removed fred off), Each am bs iit awitcho det when ‘am is fly extended (ou. Thee sno fit switch to defect when Fa ‘etd Assure that 2 seconds scent ine to trac am when contol ‘When the stan switch presse (umed on) forthe rst ime ay the station ‘sume there iso box in th station and waits forte potoelete eye fo eat the frst box and perfor the operation cele continu, Pressing the set sich when th mechanisms aleady ranting mst have oft Whea he stop ‘switchs pressed (ured a, the operation should stp (pans) buoy when the368 Sequential Applications See fing pst down or feng shod, Peming he fan rich whe Oe ‘pean of he ston is pase cases the son fo Tue 18 suspended operation. There i @ RESET_PB switch that when 09, restarts the operon. When [RESET PB ison, the era sat ies tht th adr op program ass there ino conga borat the sation, RESET PB mun be ignore if the ‘pean is runing, RESET PB only ha effet wen the operation i aeady sed Assume the following phys inpts nd ouput, Descition Stat push butonN.O, on when stating ‘Stop push ato, N.C, of when stoping Reset push buston,N. ©, om whem eon tation nit el Photoelectric sensor, off (pen) wien box isin stain. FRONT ELS Frat lp cam extended lini switch, on when extended BACK ELS Back lp ram extended limit switch, om when extended RIGHT ELS Right lap ram extend imi sith, on won extended. LEFT Ets, ‘Left lp ram extended limit switch, on when exened CONV MOTOR —Conveyormotr contol, onto move conveyer GLUE-SPRAY Glue sprayer contol, onto spray aus. FRONT_EXT Foot flgram extend dectoa convo, ono exten am BACK EXT Back fl ram extend direction contol, om extend rm RIGHT EXT Right flapram extend sireton conto, ono extend ram LEFTEXT Left fapram extend direction conto, on extend ram, ‘The arses associated wi the physical ieputs and outputs at: arias ‘Moison PLC:S ContolLogix_Sismens_GE-Fanac START PD. 100001 KO100 LaealtDst40 40 SRI stor FB 10002 LOLOL LacalLa.Dat, 4A RESET_PR 10003 KOLO? LalLa.Dats2 42 PEL q004 LOLS LoealtaiDat.3 143 ssa FRONT ELS 1000S KOW0S LoealtDad 4a Saas BACK ELS 100005 HOLS LoealiLDats 143 S86 RIGHT ELS. 100007 E0106 Loeal::LDas 14687 LEFT_ELS 100008 LOLOT Local:.Dat.7 47a CONV_MOTOR 000001 0.0200 Locu}20.Duu0 O80 QI GLUE SPRAY 000002 ORO Loeal20.Duin1 Q81— 4402 FRONT EXT 000003922 Local2-0.Dam2 _Q62_—-4Q3. BACK EXT 00004 040203. Loedl:0.Daa3 O83 OH RIGHT-EXT 000005 ©1024 Local22ODutd Q84 —_ %Q5 LEFT_EXT 000005 0.0205 Laesl2:0.Duas ODS OSPROBLEMS 369 6.2. Htc Process Control Implement he program or the allowing atch process ha mines two chemi A diagram ofthe equipment x shown in Figue P62. When the stu switch is resid ted on) fr the fit inet sit the operation te tank i filed with Ingroien upto Level A. Aer a2 scond wai. fhe tank filled with Ingredient Bupto Level B. Assume Level Bishigherthan Level A. Afr another 2 scond ‘elt the timer motes ured on for 10 mites. The the tanks empied. The ‘TANK EMPTY sensor must be coaiauosly am for | inate to ensue tat he tanks completely empty. Aferth tank ie, the process operation ished and does pt start again unl he start push ut is pressed. The operation does notrepeat. Pressing the stu sich when the operations already running mus have no ‘effet Whea the stp sich peso (ned of te apeation shoud pause at the curent sep and ll uipals mut be ffl ier values ust be resined ‘ering pe, Presing the wrt itch wie the operation the tation paused “nines the tonto resume ts pended tp. A separate overtide switch is provided to din the esting of the materia indhotunk ifthe operation hasbeen pause. Te overie switch shouldbe ignored if the operation nt aleady paused. When the oveide switch is pressed 1 Ingroint A Igri re Motor Tank Drain sous Figure P62. Batch proses370 Sequential Applications pty th tk the yin peat ull una inl he TANK_EMPTY Scsorisomfor | mine cnet the tanks completely emp), The operation ‘inno be rex uti he ak emptying complete Assume the flowing physic Vash START PD. Sror Pa FSA FSB TANK_EMPTY OVERRIDE sou soz sous STIRRER inputs ad oupus, Description Str push buon, NO, on whoo siring. Sip push to, N.C, off when sopping. Flat eve A sensor N- On lose when evel of atria tank eat est evel A lat evel Besar, N-O.-on (ose) when evs af tei in tanks teas ieve Bi, “Tank empty ser, on (closed) when ak is my Ouiletoveride, NO, on (less tt ak dining. Ingredient A sleoid om allow ingredient At ow into tank. Ingredient BS solenoid on allow ingen B oo into tink “Tank ott solenoid on © empty ask Stier moter conto, om ora sie. ‘The adress associated with the physical input and opts are: STOP PB FSA FSB TANK_EMPTY OVERRIDE Sout so12 so’ STIRRER Madicon PLCS Conwollogis Siemens GEFanve 0 Toot E9100 Lec t.Datao vats [0002 LOLOL Local:tDaa) LR [00003 LOW02 LoealtData2 42K 10004 LOWS Lalas M3 1000S HOWOS Locales 4a 10006 HOWNS Loal:iDatus 145 00000100200 Loail20.Daa0 60 (00002 050201 Loeal2:0.Data1 8: 100003010202 Loeik2-0.Dara2 82 000008050203. Loeak2-0.Data3 QR "rs rans Transfer Staton Cone. plement he program othe tllowing ton ha transfers par oma conveyor packaging machine, Figure Pa shows the yout of station tha ran pats fom a conveyor ‘o a puckaging machine. In summary, 6 parts ae led onto theta, the ‘ables tured 90" a hyralicram extended o push he pat ito packaging ‘machine, and th ram ert Par ae placed nthe bl conveyor another machine. The parts move down te conveyor ad then oto the uma Vertis walls on the tunable make sare the arts move aight inthe atable- The sage of pars othe tunable i detected bya potolectrs sensor, PEL, Bat tus OFF when a pat intr the beam. PE tas OFF just the pat ves ‘ono the fumble. After 6 pars ae onthe tumble, the tumble is rottedPROBLEMS 371 Conveyor | [7] 2) Motor | 7° (undeea) Hydaie Ram o Figure P63 Pars transfer station; () sqipment (ler log for Run nd Rese counterclockwise 90° by astvtng the tunable motor, MOTORI, fr I scond After the tbl rotted the hyralic ram extended by tung on SOLL wnt limi switch LS closes. This operation pushes the prs in the packing machine ‘The am is then retracted, by tuning off SOL, wil limit switch LS2 class, mor, MOTOR2, mst be topped ‘That isn nero col, Run, that son wea the operation is esbled. The Ron ternal coils st by another at fh ae lg, When the Run col sof, alloumtr values must be reli, nd the lar loge program must ena in {estate in which th Ru coil changed fom onto of the Run coll doses of ‘when moving the trtble, MOTORI most contin or a aston othe ‘eat tp when the time compete, Thee i ater intra coReset, tat ‘ena estar the operation. Te Ru interac ety another part the Tad loge, When Rest i 0, ital courtesan times are res andthe eral tat i so tat he Inder logic program asics 0 ars eo the372 Sequential Appiations Tadd loge forte Rus and Rest eis shown i age P6 Assume the following physical inputs, physical opus, and internal cits ‘arible Per 1st 1s2 Sout Moor! MOTOR? Run Reset Descrinion Photoelectric sensor of (open) when part passes, Ram extended limit switch, om (lose when rm is extended am react imit switch, om cone) when rm ist Pocumati ram extension selenoidconol om exendan aff “Turable motor contol, om ot unable Bet conveyor moor cot, on ou conveyor Internal col, om when operation cable oan (et by anoter art ofthe lad ogi) Ina coi en 1 eet operation (st by anor pat ofthe Tadd oi) ‘The adress asocated with the physic inputs and ous re: variabie Per Ist 2 sou MOTOR! MOTOR? Modicon PLCS Conmllagis Skmens GEFs “The internal variable rosso at types ae: Variable Run Reset, 00001 HOL00 Lealt.Datg0 0 SARL 100002 HOO! LocaltDatat 141s 10003 HOW? Loeal.Das2 42a 000001 0.0200 Lacsl20.Daao —Q80 QL 000002 0.0201 Locsl2:0.Data1 O81 02 000003040202 Loeak2-0.Daa2 G82 03 Modion PLCS ContolLouis Sismsns GEFamus Dun Type Add Data Tyas ‘Ad, Ade BOOL BMI BOL. ABI %AB9 wOOL #2 BOOL M32 sao 6-4 ag Sealing Satin Control. Implement the program fo the folowing ation a seals plastic bags Figure P6 shows he layout ofa sation that els plastic gs, Assume the bags aaa wth pct. Upon sarap the conveyor mtr SON nl the poset “eye” sensosa bag inthe station When a bags inthe station the oaveyor i stopped andthe bag is ele by the lowing tp: ‘A mechanism using ir eyinders is usod wo push two heated ars ‘ogeter ane bron each ie ofthe Bat), The bar are heli topter for 1 econ, an ‘The bars ate moved apt, ‘The mechanism we to move th heted brs is driven by a duble-aton linear pacumatie cylinder cmt by two outputs Oe deen pt ‘neryied the mechanism ves and oops moving as lng power i piedPROBLEMS 373, ° Figure P64. Bag sealing tation; (rn view: (view rom side, bas apa) view from side, bars together, (umd an). The mechanism stops a its cue! position when powers removed {cumed af, The mechani wll not move Hf bath opposing directions ae ‘ergizedsmalansoily (oa nd), Litt switch LSI ison Wen the two etd bare are oper. Limit swish LSD som when he bars have bea moved sulin fa apr. Whos the bg sealing operation scomplete urs have ben ‘moved apa) the conveyor motor tamed on. The sealed bg is moved ou of the ‘lmton,and the conveyor continues o ran ula ae ba moves into the station, tele" wlan sens that there tsoagin the station aero sealed agi moved oa When the stat sich is pressed tured on) othe fist sim onl he tation assumes there tno bag inthe tation, and Waits forthe photoes "ej 1 ‘etch is bag and perform the operation cele continuously Pressing the stat ‘sich when te mechinism sae running mist have no ffs. When the sop Sich is essed (ural of, te operon soul stop (pase), but oly when the ‘onveyor bel moving. The option MUST pot be stoped wile the bas are Ieing held together or when they ae beng moved Pressing the sa sich while the operation of the station pad eauss the sation fo resume is sspended ‘operation,374 Sequential Applications ‘hee is 2 RESET PB swich tht wheo on, estas te operation, When RRESET_PBison, the nical stat sto that he adr loge program sss ‘here iso plats bag attestation. RESET_PES must be ignore he sation notalreadypausod Whes the staan paused and RESET. PB spresedand then ‘essed, thenext pro hearst tented she is ime the stat 6th ‘spresa Assume the following physical inputs and ouput, ‘arise estintion START PB Sur pus but, NO. on wien suring. sror PB Sop push uta, N.C, off when stoppin RESET PB Rese push butlon, N- 0, when reson station ini Pet Photoelectric sensor, of (open) whon basin station st Limi swite, om close) when two heated bars are together cs Limi site, on close) when heated bat suit ar apart MoTOR Conveyor motor contol, om move conveyor BAR IN eated br mechanism in cont amt move bars together BAR OUT Heated bar mechanism out conto, ono move bars apart. “The adresses associated wit the physical inputs and outputs at: Varah ‘Modicon PLC:S ConolLogix Siemens GEFane START PB. T0001 EOL00 LacalLaDstg0 0 IRL STOR PB [00002 EOLOL Local:ta.Datat 4 RESET_PB 40003 L0W02 Local:tt.Daa2 42S PEL 10004 40103 Loeal:Dua3 143 Is} 1000S KOW0S Loeal::LDwmd 14S 1s 100005 HOLS Leeal:LDamS 145 NG MOTOR 000033 OVI LoeAl3:ODaa9 QI %QL BAR IN 000035 O0V3 Locals QI %O2 BAR OUT 00036 O04 Loca? Qs WO 'o-s. trba Elevator Conte, Using me ust char appOAER pleat he Progra forthe following elevate that moves cans of erbia (a meta) pow tom the fst Near the ssond floor ofthe factory. ‘The memobelow describes the operation of the erba elevator. A simplified dawing of the levator eshwn in Figure PS, Te: A. Doe From: 8 Smith Subject: Contos for Eiia ElevatorsPROBLEMS 375, ‘We nee to design an eleator to move cans of eri fom the fst Noor othe second Noa. Reer othe drawing ofthe elevators fr site reference numbers, The general operations described as flows: 1. The patfonn iat the lower postion so tat LS. sated. 2, Press PB_1 switch, The motor starts in fowatd and ives the clewsortotieup postion whereL, 2 nated. The mole tops. 3 AIRCL_1 is actuate and drives at for limited tine, Then it ‘everest the erated potion 4 PS (of indiates hat the elevators lear. 5. The motor stats in eves to lower the plato the tom to setivate LS. The tr stops. 6. The jog butions dive the motor up or down. Between the fit sith, bat not when in automatic coool These itches are intended for moving the elevator ar an emergency stp and for dkiveoublshoning Thy sul be ignored the moto i ander ‘stoma contr "Noes operation memo 1. The wo motocoatols (MOTOR _UP and MOTOR_DOWN) comect toa motor contol tha drives the moto 2 Only one apt, AIR CYL. 1, igus contol he poeumati einer (ran) that Dashes the can off the elevator, When im, ce am moves out fly xended postion andreas there (a og ACYL stays an). When of ‘heram moves tothe etaced postion, iota thee. Thet are no switches te dtc when the ram ily extended or retracted. sume that TO seconds are equi uly extend therm and 1S soconds will assure tht iis ally reacted ‘ven AIR CYL_1istamed OFF $5. Pressing the JOG_UP sich should have no eet if th platform sia the upper ‘ston op) oe when he JOG, DOWN swrch i aleay prea. Als, pes {he JOG-DOWN switch sould ave no eet the platform i nthe lower ‘poston boom) or when the 10G. UP switchs already presed, Both switches Should hve no eff the elevtris moving beween Meas Because the operator peso the PEL switch 4 Since the gute closed switch and the wo emergency sop switchs re wired in Serco one PLC np th ladder logo canonysethamasone swish E-STOP. ‘When either Estop sich is pesed (ESOP input sf the elevator should immedi stp, and the JOG_UP and JOG_DOWN switches mst be wed © rovethe levator When he E_ STOP intial he JOU, UP and JOG, DOWN ites shouldbe ignored ‘5. Dose concerned wth hth cans replaced on the platform when tis inthe Tower postion Assume the following physical inputs and oupus,‘316 Sequential Applications Motor c= 298 foor AIREYL_ a Ti 1st oor Front View Side View ® care Sep E-Siop Gam, Lower Umer Po 106_U?_J06_DowN a a o Figure P&S. Erba elevate: (a eaupeen: (safe related and operator sith, Deserision iit itch tht loses (on) wn elevator platform in the Tower positon Limit switch that loses (on) whem elevator platform isin tbe ‘upper positon Limit switch tat class (an) when a can ison the elevator ‘lao 1.0, pus button, on wen tring the levator operationPROBLEMS 377 Estop N.C. push baton off when stoping 306. UP 1-0. pushbutton, ono og (manually move) platform op JOG_DOWN NO. pushbuton, on jog move platform own AIR.CYL_1—_-Proumticramestensio solenoid nt extn am, offeases MOTOR UP Elevator motor conto, 0 to cause elevator plan to move ‘poh no eet on platform positon MOTOR DOWN levator motor coal, on cause levator platform to move own offs no een platfonn poston ‘The adeesses associated with the physical inputs and oatputs are Variable Modicoo PLCS ConvolLogis Siemens GEFan ist 0001 FOL00 Loca 1Daao 140 iso 00002 YOVOL Lesa 4am KA 682 Pst ood3 10102 Lesa I.Data2— 18283 Pot 100004 101/03 Loca Daas 183A E.stop 1000171020 Loesk2.Dstu0 180497 30G_UP noi 192001 Local24Daw! 1148 306_DOWN 100019 192/02 Locai2.Dau2 18249 AIR_CYLA 000033 0:0300 Loel:0.Dsa0 120 403 MTOR UP 00034 0.0301 Loeal3:0.Daa1 121 04 MOTOR DOWN 000035 O.0842 Locak3ODuu2 1220S 6-6 Transfer Station Corr Using the funtion cart approach, implement the program forthe flowing sation tat groupe and trannies parts om one conveyer to ante conveyor Figure P66 shows the layout ofa station that antes items fom one conveyer to anther. The tems ae longa actully hang ver he sides ofthe fenvejor So hat they can be asl pcked up and tansfred tothe other fonvejex. In summary. four items we collected at the end of the inbound Conver, ata mechanism executes he following moves to transfer the tems {he outbound conveyor ‘Move op 3 nwa i gro tems), ‘Move ight othe igh postion “Move down othe lowerpston(oputitm on cuthoun convey), Move left tthe ft postion ‘The dietions assume a person is ooking pte inbound conveyor and down ‘he outbound conveyor lathe lower poston, the ams can move horzotally ‘toot interference (rshing it he conveyors). Te operation ep Photoletric sensor PEI is used detache items ashy earthen of he Inound conveyor. PEI tums off as each part pases. Thre bat above the ‘Conveyor gaia wih th ems collet fore they are Wafer to the other Conver. PEI detects the oar tem (PE ums of just before the tem bits the376 Sequential Applications Conveyor Coaseyor ‘Ceftmost positon Rightmost position sip ae Inbound Tense Conveyor Mechanism i= LOH I cytnde © Figure P66 Transfer sation: op views (side view ‘te seeay stopp, and dos not tr bck on at the group of tems as ben ‘moved of the mound conveyor Limit switches LSRT and LSLT indisto the right and eR positon, respectively ofthe tansfer mechanism. Limit switch ISDN indicates th lower (down) postion a the twansfermehaniam, Tere io lini switch ht indicates ‘ho upper positon ofthe transfer mechanism. ‘The horizontal an vertical movements ofthe tafe esha ae each shiver Joube-aetoa ea prcumatieyliader arasnpiowering ant ond 2 rghtwardetivard uni. Each eyladr i controled by two ouput. Once ‘icton ouput enraze, the mechanism moves ap hes moving slay power is applied (ured on). The mechanism stop curt poston when Power i removed (ured off. The mechanism will ot move if both opposing ‘Srcton ate energized simultaneously (ef and ih, ‘The inbound conveyor motor cat, IN_MOTOR must be om whenever the station is runing. The inbound conveyer isnot tail off le the taser ‘mechnism is moving. Assume the ems ae spaced far tough ht he tanfer ‘mechan retro the inbound eonveyor before te not tam comes down the ‘eer, Your ladder has po conta ever be oulbound conveyor marPROBLEMS 379 ‘Upon ins startup, ssune tere are no Noms present tthe endo he inbount conveyor. fhe stp sith i pesed at anytime the station operation Should pause, excep when the afr mechani is eig lowered lice the ies ca the outbound conveyor The operation must mot pause whom the Incision loeed (otherwise the pats may not emsin ka group ifthe enveyor caches one tha is just barely touching the conveyor). When he sat Sich i presed wile the operation fs pausod the station shoul resume the "pended sep. When the san spatsd al ave ouput are tuned of ‘A seprate reset switch i provide which ees any item sats 0 that whe the statute pest, no tems are assumed preset th ellen Ber ‘The rset swith should be ignored if the sation fe anrng. The operator is ‘espensible orang the uray siches to move th transfer mechani ek the staring position. The operator mast old dowa the eset push btn staon ued} wile manpulsting the jog itches Asse the tolerance on al ime aes is 0.1 scons Assume the flowing physical input and oupus Variable Descrintion START.PB Stat push buton, N.O.,on when stating. STO? Pa ‘Stop pst baton, N.C, off hen stopping RESET PB Reset push but, N. 0. om when restoring sation oii et Photoelectric sensor, of (open) item pss (ce above) tspw Limi switch that loses (om hon ras mocha isin tbe lower poston user Limite that loses (om when transfer mesa is inthe rips! positon isi Limi sitet that else (om when transfer mechanism sin tbe efinost poston 206_ur Jog upton, N.O, ont move mecanism up when ese. 30G_DN “Tog down boa, NO, tomovemechanisn dawn on eset s0G_Lt Jog lef ton, N. ©, amo move mechanism Te when reset 306 RT Jogrightbaton, NO, onto move mechanismright when rset ureye Raising coma, on to ase mechanism, of has no eet. DN CYL Lowering contol ono lower mechan, af has eet chow Left motion conta, on to move mechani Jt ff has no fet. RrevL Right motion contol am to move mechanism right, ff as no fet. IN_MOTOR Inbound conveyor motor contol, om move conveyer. “The adress associated with the ysl pus and oupus ae: Variable Modicoo PLC: West SimensGEFamus START PB. 100017" 10200 Locai24Daao R087 sro?_Pa. 100018 102/01 Loca: 24.Data1 R14 RESET_PB 100019 102/02 Loea2.Data2 2 “AS380 Sequential Applications LSDN [00021 E0204 Local:LDaiat IRA AL user 10022 4N205 Loeal2:LDainS ISB isir 100023 40206 Loea2:LDans 6B 30G_uP foqoad 0207 Laeal2:LDula7? 187 10G_DN Jo0025 E0210 Loeal2.Daas 190 salas soc ut Yo0026 LORL Loesl2LDaa9 19.4806 soc _Rt 00027 L02/I2 Locai24.Da10 1923407 ur eve 100033 0.0500 LeeakSODatg0 QI20 013 DNLCYL 000034 0-301 Leeak3:0Daat QI21—%QIE “rcv. 000035 070302 Lecak8ODau2 QI22 AQIS reve O03 0303 LocsL¥ODakx3 —_QI23 MQI6 IN MOTOR 0037 OO304 Loeik¥O.Daiad —QI24 QI 6.7. Conveyor Transfer Staton Cont Using the fnction char approtc, plement the rogram forthe following sation that wants Does fom ene conteyor anne. Figure P67 shows the layout of sation tat trnsfer boxes fom one ‘conveyor to atoder. The abound conveyor consists of roles and hs bones place upon tb ater achnes Te outbound conveyer ia bela moves te ‘boxes up wo an overhead enveyorsyaton In suanary. each bx is individ ‘Pushed tothe outbound conveyor Of eure, the ext ox sot moved ul the ation fread to move ‘Upon nti star-p, the station waits ors boo rive atthe gt ndted by BOX PRESENT poineecne sensor Being on). The gat ensres tht bores ae tasfered one atime. When a box is presen GATE. SOL i activated 0 ho down the gate so the box can move i oat ofthe am, When fe box as seh pate, BOX PRESENT become ffand then GATE. SOL isturodof, Fsing the gate and preventing the next bo fom ening ul he ist box moved tothe outbound eonveyor. Assume tht tho Box i vel past he ate fster than de box behind moves down the inbound conveyor, 30 tat thee 8 Seam etna etre rs Tafel Conger conv MoToR: Cael ane Flgure F610. Pressing station (side view).PROBLEMS 349 ‘Upon tat pressing a te SIAKCL_P, assume thee ae mo pices in he station So the nfs conveyor must be red on to ring in «new wood pee. ‘When pies isdtete bythe proximity detector, PROX, the felon happens The conveyors stopped ‘Te hyralic pres (withthe dis lowered int positon. ‘Pres the pigs for 3040 seeds. Daring hs tin, he iam valve STEAM VALVE) soponodto provide heat and misret thee “The hye pres rae, Allow the ptt coo for 4541 scons Cooling cannot be started nti ‘the hyaralc pes scompletely raed. Activate the conveyor a bing pce inthe ation (and move ‘out the pice ja presse), “The operation then repeats ‘The infeod conveyor (conlld by CONV_ MTR) must be run inode ing a pice ino the sation or move tout the sao, The conveyor mustbe of ring al oer ep. “The eos sensors acest infrared sens, PROX senses the ean ‘ge ofthe plo jst before the proper portion. The time required to sop the ‘Someyor wil place the piece int the cot porn. You ts ssome that PROX roranw om daring the pressing an cooing tp, “The mechanism wet ower and raise the press consists of singe action Iya solenoi. When the PRESS DOWN ut is energize, he pes ‘moves dow od continues mave down slong owe i aplied ured on) ‘When the PRESS DOWN ouput is de-energzed, the ress moves up sad GIL ee ® at aan cute oa os eo mpi ia ® we P20 Pai) pv 0) vi. All de consejos are colle by your PLC. The outed sonvsyoe (contol by OUTFEED CONV) ison tal ime tht the palling ation running ‘The pallet conveyor tanspors empty alts in poston tobe pushed into he puller. The pallet sonveyer moor contol, PALLET. CONV must heen ‘move the empry pallet into positon PALLET CONV most be ofall het conveyor meta conta, INFEED-CONV mist beam to tanpt bs ito the Station INFEED. CONV must be off whenever th fl pallets Being moved oot ‘nda empty ple moved in Proximity sensor PALLET PROX i though enor tht off wen the mpty pallet sin poston tobe pushed in he alter tras om sho ae theram pushes the pat into the pallet. Proximity seasor BAG. PROX tun oma the bag fills othe alla tis ‘only momentary (about | second) the falls tothe pl Aste te Bags ected a fills ono the ple. Assume thatthe oduct hae ae sped ae ‘enough par 30 that BAG. PROX is off tween basPROBLEMS 423 “Thera hat pusher sn empty pallet onto th pling arsixasinle-ston| ‘nyérulic cylinder, contoled by PALLET RAM Once the PALLET. RAM ‘uit is energies, the am extends and pues the empty palit the flletizing rea. Two limit switces detect to posion of tear. PALLET ELS ‘som when de ram is extended (pale palling ate), PALLET _ RLS om sven thera is rated “Theram hat pushes tell alt onto the outed comveyor isa single action ‘nyrulic evlndet,conwolled by OUTED. RAM Once the OUTED_RAM eutput ‘energized, the ram extends and peste alt onto the otfend conveyor Two lt thon tet the postion of ther. OUTFD ELS 0m when he rams extended (pallet om ote conveyer). OUTFD_RLS is om when the ram is reacts ‘Whe he stan switch pressed (tumed on) forthe fstsime ony the sation ssumes tht pallet sinh stan. Whe th sop swith spree umod af) ‘he operation shuld pause and al cuits mast be tamed af. Pressing he start ‘ich while the operation oth station puso causes the sation este is Suspended step. When paused do not advance to the next ep ‘A seprate reset switch, RESET PB, i provided which resets any intemal states that wen testa sith presse no alts are assumed preseot inthe ‘tion, Obviously, the operator mus lear everything ou of he plleizing area ‘ere resuming operation afer reset operation. Alo, the ese operation shold «use therams to eta the ese operations not empl unl both ams are reacted. Therese switch shoud be ignored if the sation is anng, The sat Sich should he ignored whon the fset operation isin progres the sation is puusedand RESET PIS ison, the operator must cease le RESET PB before the ‘ar pushbuton switch ean be usod to reat the palltie, sume the tolerance onal timer vale is 0. seconds. Assume the following ysl inputs and ouput, Variable Desc START PB Str pus bution, NO. on when staring. STOP PB Stop push bution, N.C, ff when sopping. RESET. PB Rese push buon, N. ©, on wen festering sation tinal PALLET.PROX Proximity senor, tur ff (open) when ery plein positon 1o be pushel inn palleizer om as allel is pushed eto Palcuze or when po pallets presen. BAG_PROX Proximity Seasor, tums om (lose) momentarily as bg fl to pall. PALLET ELS Limit sich thar closes (on) whon emp pllee- pushing inde is extended emp pallet in pallet), PALLET.RLS Limit switch that closes (on) when empty palit pushing linge is reacted OUTFD_ELS Limit svc hat closes (on) whe il pallet pushing cylinder ‘sextended (pallet on outed convey). OUTED RLS Limit switch hat closes (o) wheal pallet pushing eyider ‘erected424 Sequemtil Applications INFEED_ CONV Infed conveyer motor contol on to move bags ino station, OUTFEED CONV Outed conveyer mote conro, ono move fl pallets to next PALLET_CONV _Eimpy pallet conveyor motr contol, ono move empty pallets mo posito o be push int paler PALLET RAM Empty pallet slinder extend conto, om extend yin, off | ‘uses lind to rete, COUTED_RAM Full pallet cinder extend contol on to extend eylndt, off Gaueselinde f evac ‘The address associated with the physical pus and opts ae: Vasile Madicon PLC. Conmollogit Stamens GEFanue START PB. FOL00 LocaktLDaiao M0 AL sror Ps TOOL LoeakiADwal L402 RESET. Pa YOIN2 LocikIADwa? 2413 PALLET PROX LOWS LosabIADa@s 143 ld 114 LocakIADaad as PALLET ELS TOUS LocakLLDaas 56 PALLET RLS Loeal:LDans 14687 OvTFD ELS, ocala? 14.78 OUTED RLS, LoaltiDaas 150 $19 INFEED CONV oo6001 0-020 Locs}2;0.DaK0 980 QI OUTFEED CONV 00002 0-901 Loeu2O.Dua.1 O81 QD PALLET.CONV 000003 0-022 Local20.Daa2 O82 Q3 PALLET RAM 000008 0102403 Locl20.Daa3 O83 ‘Qt OUTFD RAM 000005 0.0204 Lecak2-0Daias QR OS P21, Revisod Pats Tranter Staton Control. Using th faction chart approach, implemen the program forthe following revision to pars tense sation, Problem PE. describes a station that ransfer pars fom a conveyor to 2 packaging machine. The parts ae now made faster and so the cele ne ofthe pars ransfe ston of problem P63 must edeteased, Specialy the loading ff the neat 6 parts ont the fable ats we the ren pushes Prt inf he Ducking mahine, Assume thems ace to extend a ett he a es han the ime to aecumulte6parts onthe able, 6.2, Revised Ding Staton Control. Using the function chart ppach, plement the rogram forthe folowing revision the dling ston, Rework the dling station of problem P68, allowing cen operations to occur in parle |. The extensonretrction of dil 1 and dil 2 ccc simutncously. However, make o assumption about which driling operation Sises astPROBLEMS 425 2. Allow new part to move ito positon 2 whi the revows prs being drilled. However, ow part cannot move om positon 219 son 3 wil drilled par moving ut of poston 3. ‘The assumption about iil statu doesnot change. Upon intl statu, aus ta there reno pars waking et gate 1 and ht Gere co prs a hs Staton waiting to be dil. DO NOT init iling operation wl the Sst art moves into the station. 6-28, Revised Bolt Driving Station Coto, Using the anton cat approach, ipleent ‘he rogram forthe following revisions othe bl diving station of problem Pe Rework the ol diving station of 6-19, allowing cern operations o acu in pale: ‘While the bolt driving mechanism i lowering othe comet poston, convey ll bolts into positon Make no assumption abou which pain shes st ‘Ako, he tation now conveys and drives 6 hots Assume the following adltonal physical inns and ouput. ‘atiable vivs.cis Gvivecis GvLys.cts, Gvive.cis PROXES PROXBS Roxas PROX BOLTS CYL PBOLTA.CYL PROLTS_CYL WWLV3 aviv Guys Guys cvLvs cvs cvs Destin Limit svt hat closes (om) when gte valve ily else Limit svt hatcloses om) when gt ale fully else, iit switch tharos (on) when gate valve is fully closed “Limit switch tharos (on) when gate vale 6s uly load Proximity site ta iam when Bol #3 9 pon fo be ‘ven ‘Proximity sich tha nm when Bolt #4 i in position tobe ‘ven, Proximity sviteh ta ia on when bot #8 i ia postion tobe ‘ven, Proximity sith tht in om when bol 6 sn postion be ‘sven, Pushes bolt #3 at pacumati tube, on extend off rests Pushes bol #4 amo peumai ruben extend off erst Pushes bol Sto cama tbe, extend ff erat aale Dl HG esi bo et fr Closes gate valve #3 10 sea tbe, ono clos, of 0 open Closes gate valve # sea tbe, onto close, of open Closes gate valve #8 Sea tube, on close, off open Closes gate vale #610 sal tube, ono lose off open ‘Opens convey valve #3 to convey bolt #3 to diver, om © open ave oo cos. ‘pens convey vale # © convey bl to diver, ono open ‘ale, oo close. ‘Opens convey valve #5 to convey bl #8 to diver, on open ave, aff close4226 Sequential Applications extve ‘opens convey valve 210 coavey Bot 10 deve, om oops ave off cow, AMOTORS ‘opens valeto ir mor trv bot #3, om rote bol, off AMOTORS Opens valveto irmotar #0 diveblt 4, ono tate bo of AMOTORS (Opens valve to armatar #8 wodeivebolt ¥S,entorotatebot off AMOTORS Opens altetosizmotors6to dive bol #6, on orotate ol of ‘Tie adress associated with he atonal pial inpts nd ups ae ‘Vasile Modicon PLCS ConolLoxix Siemens GE Fane Gvivs.cts W003 KO8/12 —LocalsDut 10 tes avivsets, 100084 EOS/I3 — Loclt.Dat 11 ates GvLys-cts, 0004S LOWS Localt.Dua 12 ates cute cts, 100046 LOWS LocaltL.Daa 13 6 PROXD [00649 10800 Loeal$:1Dat.0 ato PROXDA [0080 LOSi01 Leal Dats satso PROXBS 40st KO5W02 —Leal5L.at.2 satst PROXBS 10052 HOSI3 Loeal$:Lat.3 sa PROLTS CYL 000023010616 Locak6O.Duas G26 KQRD PROLTHCYL 000024 106477 Loea6O.Dua7 Q247 5024 PHOLTS-CYL 000028 010610 Locai6O.Daas Q250 54025 PHOLTSCYL 000025 010611 Local:60.Daad Q25.1 "4026 Gviy3 000029 06/14 Loeal:0.Daia12 254 %4Q29 uv 000030 0.6/5 Leeals:O.Data3 QI55 %4Q30 Guys om0n31 06/16 LocaksO.Dat 8 256° %4Q31 vty 000032 0.0617 Loeal60.Data15 Q257 4092 cvs 00035 0.0702 Loeal-7:0.Daa2 Q282 “4035 cvs 000035 0.0703 Loeal-7.0.Daas Q283 “4036 cvs 000037 0.0714 Loedl:7.0.Daad —Q2x4 O37 cvLvs (00038 0.0708 Loesl:7.0.Daas QDS O38 AMOTORS (00041 0.0710 Loaik7.0.Daas 220% AMoTOR! 000012 007/11 Leal ODamd —QBP.1 Sued AMOTORS 000083 0.0712 Lexal7.0.Daa.10 Q22 Yet AMOTORS 000044 0.0713. Loeal7:0.Daa1 Q23 Qs 624. Trafic Light Controller. Using the faction char approach, implemen the programy forthe flowing tfc gt contr, A diagram of the intersection is shown in Figure P62 Fr simpli, the afi igh are re or grevn. Tet te no yellow ight. The operation ofthe trafic light contol broken up ino cytes. Daring ‘he norh-suth (NS) yee, ortibound (NB) and southbound (SB) sah aticPROBLEMS 27 Piqure P24 Suet incrseton, ns a ren signa, andthe signals eal ther lanes are, Daring an east-west (GW opel, eastbound (EB) and westbound (WB) wfc hs agree sigalandall ‘the aes hae aed signal: Te lftur (LT) el is acivaed whenever a NB ‘eS cari ine enpstve left lane. Dring a LT eye the seal forthe ‘0 left lanes are ren andthe sgn fo the ter ans aero. ‘Nonhbound and southbound traffic i sven pion, and dhe contol ‘emai nthe NS cele a long ano crs ae detected inthe EB or WB ates, td ‘when eas ae inthe NB and SB Tetsu lancs. However, the NS eye 0 ‘Shorter thin 30 scons Ia eat present in the EB or WE lanes afr the ‘minimam 0 sconds inthe NSeyele an EW eyeeis inated The EW eyeelasts for 0 seconds Atthe endothe EW eel, any cas are preset in cir fu lane, the contents an LT eycle- Others, fo car ae present in ithe Teun lane, the cone reruns othe NS yee. An LT eyee lass for 10 sconds the end ofan LT eel, the controler uns othe NS oye aca ‘presen incihe eft rn lane ale te simu 30 seconds inthe NS cycle, a LT ‘jes inated ‘When he program nly rns shold init aNSyele. Ast swstehs ‘povided intate aN eye when the site Assume the following physi inputs nd ous arabe Descriton SBS-PRES (On when SB car pesca ina staight ahead lane SBL_PRES (On when SB car reset ur ane NBS_PRES On hon NB car present in a straight lane NBLIPRES On hen NB car present in ef-w lane PRES: (On when EB car present in ane WB PRES (On when WB carpreset inane428 Sequel Applications RESET 8 ese ste, ont mmeaitety mtiatea NS ele sis oR Gren signal, SB sagt anes SBS_RD Red signal, SB sai aes SBL_GR ‘Green signal, SB left-arm ane SBL_RD Red signal, Bef ane NBS_OR Groen signal, NB sight anes Nas_RD Red sia, NB sagt anes NBL.GR (Green signal, NB left-turn lane NBLRD Red sign, NB ef-s ane EWH_GR (Green signal, EB and WB lanes EWB_RD Red signal, EB and WE lanes ‘The aressesasoatd wit th physical inputs and ouput ar: sible Modi PLCS Contllogix Skmens_GEFamis SBS. PRES 09001" E0100 LocaiIDatao MO Salk ‘SBI_PRES 100002 LOLOL Locat.Datat Mt 942 INBS_PRES. 100003 40102 Lecali.Data2 M243 [NBL_PRES, 10004 E0103 Lecakl.Daa3 M3 Mle EB PRES 100005 EOLA LacatLDaas MA as WB PRES 100006 L015 LoealLDaas S86 RESET_P8 100007 L016 LowatLDaas 6 IT sns.GR 000001040200 Loal20.Daao geo OL SBS_RD 000002040201 Loeil20Daal QR 02 SBLGR 000003 010202 Loesl20.Dau2 82 %03 SBL_RD 000004050203 Loeil20.Daas 83 NOE NBS_GR 000005 0.0204 Loetl2-0.Daas QS 8405 NBS_RD 000005050205 Loeal20.Daas 08S 06 NBL.GR (000007 0.0206 Loesl2:0.Daa6 Q86 07 NBL RD 000008 0:0207 Loesl20.Dan7 987 08 EWS GR 090009 0.0210 Loeal20.Daas G20 08 EWB_RD M010 OM/IL Leeal2-0Daa9 —Qol—_%QIO