Questions on PLC and Electro-Hydraulics with PLC

Q 1. In an industrial application, a two cylinder system is used for material handling purpose.
Out of two cylinders, one cylinder grips the component and the second cylinder positions
the gripper at drop zone on actuation. When retracted, the gripper allows the component
to fall in storage container and then it returns to the base position by means of second
cylinder. For each application of material gripping, a time gap of 5 Seconds is provided
for ensuring correctness. Develop a Pneumatic circuit for the described application.
Incorporate multi cycle systems and an emergency stop.
Q 2. Draw ladder logic diagram for control of heating oven, the system is started with start
button that seals in auto mode. This can be stopped by stop push button. When auto goes
on initially it has to sound a horn for the first 10 seconds to warn that oven will start and
after that horn stops and heating coil starts. When oven is turned off the fan continues to
blow for 300 seconds.
Q 3. The figure given below shows a ladder logic diagram for a mixing operation. Two liquids
are added into a container and mixed together.
V1 – Inlet valve for 1st liquid
V2 – Inlet valve for 2nd liquid
M – Mixer
L1 – Minimum liquid level
L2 – Maximum liquid level
K1 – Relay
In this operation a further modification is to be done by addition of a heater for heating
the mixture and an automated outlet valve for the mixture. The heater must heat the
mixture after 10 seconds of mixing and the mixer must continue to work till heating is
over. The heater should stop working after raising the temperature of the mixture to 60˚C.
The outlet valve should then open to allow the mixture to flow out of the container.
Q 4. Draw ladder logic diagram for control of chemical mixing operation. The system is
started with start button that seals in auto mode. This can be stopped by stop push button.
When auto goes on a chemical starts to fill the container through S1 valve. As the
chemical fills to level A, the filing operation stops and stirrer motor operates for 10 sec to
mix the fluid. When stirrer motor stops, the discharge valve S2 is operated to pass the
chemical to further operations. The discharge valve remains open till the chemical level
reaches to level B.
Q 5. Draw ladder logic diagram for control of water heater system. The system is started with
start button that seals in auto mode. This can be stopped by stop push button. When auto
goes on the water is supplied into the heater with reference to levels L1 and L2 which
measure minimum and maximum levels of the water inside the heater respectively. Once
maximum level is reached, heating of water is started. The heating process continues for
60 sec. After that heater stops and hot water is available for usage. Once water level
inside heater reaches minimum water inlet valve is operated to allow flow of water inside
heater.
Q 6. Develop a PLC ladder logic diagram for an air conditioner control unit. The system is to
be designed in such a way that two push buttons namely Start and Stop will start and stop
the continuous operation mode. Once Start button is pressed, the air conditioning unit
display light turns on and fan motor is started. The fan motor is further controlled by a
two temperature sensors which are designed in such a way that sensor 1 is activated if
temperature inside room becomes higher than set temperature and sensor 2 is activated if
temperature inside room becomes lower than set temperature. The fan motor has to be
stopped or started depending on cooling requirements.
Q 7. When a part is placed on the conveyor at position 1, and when a start button is pressed it
moves to position 2. Upon reaching position 2, it stops for the stamping operation to take
place. After stamping it automatically moves to position 3. It stops at position 3, where
the part is removed manually from the conveyor.
Q 8. Develop a PLC ladder logic diagram for automated bottle capping system. The bottles are
placed on conveyer after filling and given into the capping system. Once a process start
button is pressed, the bottles are checked if they are filled or not. The filled bottles are
passed to second conveyer which passes the bottles under a capping machine. The bottles
are checked after capping to ensure that cap is fitted properly or not. After final checking
bottles are passed to packaging process. An emergency stop is implemented for stopping
the process in between and a process stop is used for completely stopping the machine.
Q 9. Develop a PLC ladder logic diagram for an industrial blender. The pressing of Start
pushbutton ensures continuous power supply to the blender which can be stopped only by
pressing stop push button. Once power supply is given to blender motor, the motor starts
to rotate. The controller has to check that the lid is closed before starting motor rotation.
In case if lid is not closed, a warning horn must be blown for 10 seconds which will
notify the concerned authorities.
Q 10. Develop electro-hydraulics circuit with PLC for sequence: A- Delay B+ (A+B-) Delay
Q 11. Develop electro-hydraulics circuit with PLC for sequence: A+B+A-B-
Q 12. Develop electro-hydraulics circuit with PLC for sequence: A+B+(AB)-
Q 13. Develop electro-hydraulics circuit with PLC for sequence: (AB)+A-B-
Q 14. Develop electro-hydraulics circuit with PLC for sequence: (A+B-)(B+A-)
Q 15. Develop electro-hydraulics circuit with PLC for sequence: A+(A-B+)B-
Q 16. Develop electro-hydraulics circuit with PLC for sequence: (A+B-) Delay (B+A-)
Q 17. Develop electro-hydraulics circuit with PLC for sequence: A+ Delay B+A-B-
Q 18. Develop electro-hydraulics circuit with PLC for sequence: A+B+ Delay A-B-
Q 19. Develop electro-hydraulics circuit with PLC for sequence: A+B+ Delay(AB)-
Q 20. Develop electro-hydraulics circuit with PLC for sequence: (AB)+ Delay A-B-
Q 21. Develop electro-hydraulics circuit with PLC for sequence: (AB)+ Delay A- Delay B-
Q 22. Develop electro-hydraulics circuit with PLC for sequence: B- Delay(AB)+ Delay A-
Q 23. Develop electro-hydraulics circuit with PLC for sequence: A+ Delay (A-B+)B-
Q 24. Develop electro-hydraulics circuit with PLC for sequence: (AB)+ Delay (AB)-
Q 25. Develop electro-hydraulics circuit with PLC for sequence: Delay B+ Delay(A+B-)A-
Q 26. Develop electro-hydraulics circuit with PLC for sequence: B+B-DelayA+DelayA-
Q 27. Develop electro-hydraulics circuit with PLC for sequence: Delay(AB)- A+B+
Q 28. Develop electro-hydraulics circuit with PLC for sequence: Delay A+ (A-B+) Delay B-
Q 29. Develop electro-hydraulics circuit with PLC for sequence: A+B+C+A-B-C-
Q 30. Develop electro-hydraulics circuit with PLC for sequence: A+B+C-B-C+A-
Q 31. Develop electro-hydraulics circuit with PLC for sequence: A+B+C-A-C+B-
Q 32. Develop electro-hydraulics circuit with PLC for sequence: A+(BC)-(AC)+B+
Q 33. Develop electro-hydraulics circuit with PLC for sequence: A+(BC)+(ABC)-
Q 34. Develop electro-hydraulics circuit with PLC for sequence: A+ Delay B+C+ Delay(ABC)-
Q 35. Develop electro-hydraulics circuit with PLC for sequence: (ABC)+Delay C-A- Delay B-
Q 36. Develop electro-hydraulics circuit with PLC for sequence: B+ Delay (AC)- Delay (AC)+
B-
Q 37. Develop electro-hydraulics circuit with PLC for sequence: (BC)+ Delay A- Delay B+ C+
Delay A+
Q 38. Develop electro-hydraulics circuit with PLC for sequence: (BC)+ Delay A+ (ABC)-
Q 39. Develop electro-hydraulics circuit with PLC for sequence: (AB)+ C- (BC)+ A+
Q 40. Develop electro-hydraulics circuit with PLC for sequence: B+ Delay A- C+ A+ Delay
(BC)-
Q 41. Develop electro-hydraulics circuit with PLC for sequence: Delay A+B+C+ Delay A-B-C-
Q 42. Develop electro-hydraulics circuit with PLC for sequence: A+ Delay B+C+A-Delay B-
C-
Q 43. Develop electro-hydraulics circuit with PLC for sequence: A+ Delay C- B+ Delay B- A-
C+
Q 44. Develop electro-hydraulics circuit with PLC for sequence: B+ Delay A- C+ A+ Delay
(BC)- Delay
Q 45. Develop electro-hydraulics circuit with PLC for sequence: Delay(ABC)- Delay A+C+
Delay B+
Q 46. Develop electro-hydraulics circuit with PLC for sequence: Delay (AC)- Delay
(ABC)+Delay B-