Programmable Logic Control of an Electro-hydraulic

System for a Reconfigurable Assembly Fixture used

for Press Brake assembly
Olabanji, O. M. & Mpofu, K.
Tshwane University of Technology,
Faculty of Engineering and Built Environment,
Department of Industrial
{MohammedOO; MpofuK}@tut.ac.za

Abstract - The inconsistent demand of product
configurations by users increases the variety of assembly
tasks. This situation calls for reconfigurable assembly
systems (RAS). A reconfigurable assembly system requires
equipment that will provide a gripping force to dynamic
models of products during assembly. This equipment
requires adequate and efficient control devices for effective
work-holding and accurate positioning of products. In this
article, a novel electro-hydraulic system comprising of six
actuators was designed for a reconfigurable assembly
fixture, which will be used for assembly of press brakes.
The system was designed using FESTO FluidSIM Electro-
hydraulics. The programmable logic controller model was
connected using a logic circuit, and the output of the
actuators was obtained graphically, in order to depict the
functionality of the system. The PLC was designed using
Automation Studio 5.0. The designed circuit was also
simulated using FESTO didactic electro-hydraulics
equipment in order to demonstrate uniform extension and
retraction of the actuators. Results confirm the feasibility
of the approach for practical application in RAS.
Keywords- Programmable Logic Controller; Electro-
hydraulic system; Reconfigurable assembly fixture
I. INTRODUCTION
The demands for customized and personalized products
make manufacturing and assembly systems complex and
dynamic. Reconfigurable assembly systems are designed to
assemble products with customized flexibility within a part
family. The development of manufacturing and assembly
systems for a product or customized product within a part
family is a concurrent activity that needs to be done in line with
the product development [1]. Considering the assembly system,
one of the major subsystems that needs to be designed is a
reconfigurable assembly fixture (RAF). A reconfigurable
assembly fixture is a work-holding device that accurately
locates positions and grips the work in progress part, during
assembly. The part of the product supported by a
reconfigurable assembly fixture varies according to production
requirements [2-3]. In essence, the development of a RAF
requires efficient controlling devices for effective performance
[4]. Press brakes are machine tools used for non-cutting
operations in manufacturing. Due to numerous functions of
press brakes, there are different types in use. Assembly of press
brakes starts by accurately locating and positioning of the
frame, which is the heaviest part of the equipment. Other
components of the press brakes are assembled to the frame
which is securely positioned during the assembly process.
During the assembly process, the frame needs to be clamped
with a high force so that other parts can be fitted in the correct
alignment. The motion of parts in a RAF is complex and
dynamic. A model for reconfiguration is usually developed,
and used to control the fixture either through an agent system
or a controller.
Complex motion and force requirements of RAF are
usually achieved by hydraulic systems. These hydraulic
systems are controlled by electrical devices. A hydraulic
system can either be pump controlled or valve controlled.
Valve controlled systems use electro-hydraulic valves which
are used to control the flow of fluid in the system [5-7]. The
ability of hydraulic systems to produce a high clamping force
and accurate positioning makes them applicable in the design
of fixtures and other modern equipment [8-9]. The hydraulic
gadgets are the muscles in the system while the electrical
wiring is the brain controlling the hydraulic system [10].
Programmable logic controllers (PLC) were developed in the
late 1960s to deal with the problems of hard-wired panels
which are time-consuming to wire or debug. PLCs are special
coordinating computers which are used to control the activities
of process equipment and machines [11]. Reconfigurable
equipment is controlled by microcontrollers or PLCs [12-14].
Microcontrollers use programs which are loaded on chips,
and inserted into the panel of the machine. These programs are
set to perform defined instructions which in most cases can be
reprogrammed and used with the same chips [15]. PLCs are
used in tough industrial environments. They are used to control
the performance of equipment and processes that are logical
and sequential in nature [5], [16-20]. The function of a PLC in
reconfigurable device is such that it receives commands from
the reconfiguration model and interprets the instructions to the
physical system based on a set of reprogrammable instructions
of the PLC [20-24]. In this article, an electro-hydraulic system
for reconfigurable assembly fixture was designed, and
controlled using a PLC. A logic diagram was designed to

270
control the PLC, based on some set of instructions or sequence
of operation of the fixture. The electro-hydraulic system
comprises of six hydraulic actuators which output force,
velocity and position are presented graphically in fig 9-10.
II. LITERATURE REVIEW
The construction and position control of a translational
hydraulic servomechanism for two hydraulic actuators was
done by Situm and Lobrović [8]. A control algorithm was
developed and implemented using three devices, which are a
programmable logic controller, an industrial computer, and a
combination of both. The system was not cost effective
because it uses three directional control valves (DCVs).
However, it produces an effective force control due to the
usage of three DCVs. The factors for selecting a suitable
controller were identified as;
 Compatibility of controller with electrical components, I/O
requirements and needed signal types.
 Controller operations in the working environment,
 Requirements for special features of the controller
hardware, for both local and remote process control,
 Programmability and requirements for advanced functions
and data manipulation, etc.
A double acting hydraulic cylinder with a limit position sensor
was designed by Bader [15]. Bader’s position control system
was achieved using a microcontroller interfaced with position
sensors to detect the position of the actuator. A proportional
directional control valve was linked to the microcontroller
through the PID controller, and the system was simulated
using Simulink. The analogue signal was converted to digital
values which may provide resolution errors during conversion.
The step response of the system yielded a high accuracy but
there could be an error due to backlash of the actuator piston.
A novel control design was developed by Földi, Béres, and
Sárközi [11], to realize fast and accurate position of pneumatic
actuator. The system uses a 5/3 way directional single
solenoid valve, and an analogue displacement encoder for
metering the piston’s position and velocity. The system has
the advantage of using inexpensive on/off solenoid valves, and
operates an on chatter free air compression with no pressure
sensor, making it cost effective compared to servo-pneumatic
positioning systems. However when large forces are required,
pressure requirements increase which makes it difficult for
detecting pressure.
III. THE ELECTRO-HYDRAULIC SYSTEM
The electro-hydraulic system comprises of two movable jaw
cylinders (MJC), and four finger cylinders (FC). The FC and
MJC are controlled by DCV (A) and DCV (B) respectively, as
shown in fig 1 (presented at the end of this article). Three way
flow control valves and pressure reducing valves are used to
control the flow of hydraulic fluid into the actuators, in order
271
to obtain synchronized motion and equal positioning. The
directional control valves, three way flow control valves, and
pressure reducing valves are sized in order to be suitable for
the configurations of the actuators and external loads. The
three way control valve regulates the flow of fluid into the
cylinders and also adjusts the pressures with the help of the
pressure reducing valves. The clamping force of the
reconfigurable assembly fixture is the extension force of the
actuators which varies with the weight of the press brake to be
assembled. The reconfiguration model of the fixture computes
the travel length of the hydraulic actuator and sends the
information to the PLC through a computer. The PLC sends
the information to the electrical system and a PID controller
which then controls the hydraulic system. The description of
the control architecture and operation process for the
reconfigurable assembly fixture is presented in fig 2 (as
presented at the end of this article).
The operation of the hydraulic equipment depends on the
electrical connections. The electrical components are
connected with reference to the sequence of operation of the
hydraulic actuator. The electrical system is presented in Figure
3. The part list for the hydraulic and electrical connection is
presented in table I (as presented at the end of this article). A
logic module was used to design the PLC based on the
sequence of the operation. The limit switch in the system F1,
F2, F3, and F4 were used as inputs in the module which
controls the solenoids used as outputs through the logic gates.
The truth table used for the connection of the gates is
presented in table II. The logic module is presented in Figure
4. The electrical connection was used to design the rung
diagram which is connected to the PLC cards. The ladder logic
was designed using Automation Studio 5, as shown in Figure
5. The simulation of the ladder diagram with AB PLC, and
IEC standard for electrical control is shown in fig 6.
TABLE II. Logic Module for PLC
Start/F1 F2 F3 F4 Output
1 0 0 0 SOL A
0 1 0 0 SOL B
1 0 1 0 SOL C
0 0 1 0 SOL D
 +24V 1 2 3 4 5 6 7 8 9 10 11 12 13

Source +24
K4
K1 K2 K3 F1 K4
K1 F2 K2 F4 K3
S1

F3
K1 K3 K4 K3
K2
3

24V I1 I2 I3 I4 I5 I6 I7 I8
Return Switch
4

PLC logic

0V Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8

K1 K4
SOL_D
SOL_B K3
SOL_A K2 SOL_C
Source 0
0V

3 3 6 6 9 9 12
4 7 10 13
5 11

Fig 3. Electrical System for the Reconfigurable assembly Fixture

Start/F! I1
& Q1 SOL A
I2
F2 Q2 SOL B
1 1 &
I3
F3 Q3 SOL C
& &
I4
Stop/F4 1 1 Q4 SOL D
I5

1 1 Q5

I6
1 & Q6

I7
& Q7

I8
1 Q8

&
&
1

Fig 4. Logic Module for Electrical system of the RAF

272
 RUNG1

1-1IC1.IN0 1-1IC1.IN1 1-1OC1.OUT0

1-1OC1.OUT0

1-1IC1.IN1 1-1OC1.OUT1

I: 0/0
Start 1-1IC1 1-1IC1.IN1 O: 0/0
1-1OC1.OUT1 solA
1-1OC1
IN0 I: 0/00
F2 O: 0/00 OUT0
IN1 I: 0/01
1-1IC1.IN2 SolB
F4 1-1IC1.IN3 1-1OC1.OUT2 O: 0/01 OUT1
IN2 I: 0/02
F1 O: 0/02 OUT2 solC
IN3 I: 0/03
1-1OC1.OUT2
O: 0/03 OUT3
IN4 I: 0/04
O: 0/04 OUT4 solD
IN5 I: 0/05 1-1IC1.IN3 1-1OC1.OUT3 O: 0/05 OUT5
IN6 I: 0/06
O: 0/06 OUT6
IN7 I: 0/07
1-1IC1.IN3 1-1OC1.OUT3
O: 0/07 OUT7
COM
COM
END

Fig 5. PLC connection for the RAF

Fig 6. Simulation of the PLC Circuit.

273
 IV. EXPERIMENTAL SET-UP
In order to demonstrate the designed hydraulic system and
observe the synchronization of the cylinders, the designed Finger
hydraulic circuit was set up in the laboratory using the Cylinders
FESTO hydraulic test bench. extending at
the same
The extension and retraction of the actuators was equal
rate
which signifies that the system will have optimal function
during operation. Fig 7 and 8 represent the pictures of the
experimental set-up, and extension of the cylinders during Movable
the experiment respectively. The description of components jaw
for the experimental set-up is presented in table III. Cylinders
extending at
the same
rate

Fig 8. Experimental set-up for Synchronized Extension of FC and MJC

V. RESULTS
The parameters of the actuators and other hydraulic
equipment were used to run the simulation and the
parameters of the actuator were compared graphically, as
shown in fig 9 and 10. Considering fig 9, the displacement
of the finger cylinders is equal which shows that the
synchronization of the cylinders works. This can also be
confirmed with the parameters of the actuators such as the
velocity and force. Each actuator was simulated using
variable force in order to depict the changes in each
cylinder. The increase in force of the cylinders was constant
which signifies accurate synchronization. More so the
Fig 7. Experimental set-up for the Hydraulic System of RAF velocity of the cylinders is equal but at the start the velocity
tends to be unstable as shown by the shaded area in the
TABLE III. Description of Figure 7.0
velocity graph in fig 9. However the instability of the
PART DESCRIPTION
Finger cylinders velocity is the same in all the actuators. The result is the
Movable jaw cylinders same for movable jaw cylinders as shown in fig. 10.
Limit switch
Pump unit
Directional control valve B
Hose connector (discharging to the tank)
Flow distributor to inlet ports of movable jaw cylinders
Pump switch
Directional control valve A
Hose connector (supplying from the pump)
Flow distributor to outlet ports of finger cylinders
Electrical connection unit
Flow distributor to outlet ports of movable jaw
cylinders
Flow distributor to inlet ports of finger cylinders

274
Designation Quantity v alue 7 8 9 10 11 12 13 14 15 16 Designation Quantity v alue 7 8 9 10 11 12 13 14 15 16
350 350
300 300
250 250
Position 200 Position 200
FC 1 FC 2
mm 150 mm 150
100 100
50 50

0.05 0.05

0.04 0.04
Velocity 0.03 Velocity 0.03
FC 1 FC 2
m/s m/s
0.02 0.02

0.01 0.01

32000 32000
28000 28000
24000 24000
Force 20000 Force 20000
FC 1 FC 2
N 16000 N 16000
12000 12000
8000 8000
4000 4000

Designation Quantity v alue 7 8 9 10 11 12 13 14 15 16 Designation Quantity v alue 7 8 9 10 11 12 13 14 15 16

350 350
300 300
250 250
Position 200 Position 200
FC 3 FC 4
mm mm
150 150
100 100
50 50

0.05 0.05
0.04 0.04

Velocity 0.03 Velocity 0.03

FC 3 FC 4
m/s m/s
0.02 0.02

0.01 0.01

32000 32000
28000 28000
24000 24000
Force 20000 Force 20000
FC 3 FC 4
N 16000 N 16000
12000 12000
8000 8000
4000 4000

Fig 9. Graphical presentation of output parameters for Finger Cylinders

Designation Quantity v alue 20 21 22 23 24 25 26 27 28 29 Designation Quantity v alue 20 21 22 23 24 25 26 27 28 29

1200 1200
1000 1000

800 800
Position Position
MJC 1 600 MJC 2 600
mm mm
400 400

200 200

0.02 0.02
Velocity Velocity
MJC 1 MJC 2
m/s m/s
0.01 0.01

112000 112000
96000 96000
80000 80000
Force 64000 Force
64000
MJC 1 MJC 2
N N
48000 48000
32000 32000
16000 16000

Fig 10. Graphical presentation of output parameters for movable jaw Cylinders

275
 VI. CONCLUSION
A variety of industrial applications require hydraulic systems,
because of their durability and large force. More so, advanced
manufacturing systems and equipment such as reconfigurable
assembly fixtures require the use of a PLC in order to achieve
effective performance. An electro-hydraulic system was
designed for a reconfigurable assembly fixture, and the
designed circuit was simulated experimentally using the
FESTO hydraulic test bench. The electrical components of the
circuit were connected by considering the sequence of
operation of the hydraulic equipment and the logic module of
the PLC using FluidSIM electro-hydraulics 4.0. The results of
the simulation show that the output parameters of the cylinders
such as the length, velocity, and force are equal. This signifies
that the actuators are fully synchronized. In addition the PLC
was designed using Automation Studio 5.0. The rung diagram
was connected with the input and output cards of the AB PLC.
The simulation shows that all the solenoids are actuated in
operating sequence. In essence, simultaneous control of
position and force of multi-actuator system has been addressed
in this article. The novelty of the hydraulic system is the use of
the three way flow control valve in conjunction with two
pressure reducing valves per actuator, rather than the
conventional flow divider. The three way control valve
regulates the flow of fluid into the cylinders and also adjusts
the pressures with the help of the pressure reducing valves.
This article provides relevant information in the design of
hydraulic circuits, control and automation and it will serve as a
tool for synchronization of multi actuator hydraulic systems
without the use of directional control valves for each cylinder
or actuator.
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F=-21474800

F=-21474800

F=34397

F=34397

F=34397

F=34397
F4

F2
P
P R3 P PP R9 P PR 1 0 P PR 1 1 P
P R4 PR 1 2
MJC LS FC LS
F3

F1
A A A A A A
B B
B B B
B
T T
T T T
T
FC V 4 A
FC V 3
FCV10 AFCV11 FCV12
MJC 1 A MJC 2 FC 1 A V9
FC FC 2
A
FC 3 FC 4 A

A
A
B
B

FC V 1 T FC V 2 P R5
T P A BFC V 7 P R8
B P
A B B
A A
T
T
FC V 5 T FC V 6 T
P P P R6 A
A A P
A FC V 8
P R1 P R2 P R7
P
A A

A B A B

SOL_B SOL_D SOL_A SOL_C

P T P T
DCV (B) DCV (A)

P T

PU Ts

Fig 1. Hydraulic System for Reconfigurable Assembly Fixture

277
 TABLE I. Part list for the Electro-hydraulic system

S/N Designation Description

1 DCV (A) and DCV (B) 4/3 Way solenoid valve with shut off position
2 F1, F2, F4, K1, K2, K3, K4 Make Switch
3 F3, K2, K3, K4 Break Switch
4. K1, K2, K3, K4 Relay
5 FC1-FC4, MJC1-MJC2 Double acting Cylinders
6 SOL A-SOL D Valve solenoid
7 PU Pump unit
8 RR1-PR12 Pressure Reducing Valve 1 to 12
9 PLC logic Logic Module
10 FC LS and MJC LS Distance Rule
11 FCV 1-FCV 12 Three way flow control valves 1 to 12

RECONFIGURATION MODEL
Computes the travel length of
COMPUTER
Input the length and width actuators, and other operating User the operator interface to
of press brake parameters such as gripping time, interact with the control scheme
fluid flow, extending and retarding and program for the PLC.
force, gripping force, and power

OUTPUT

Actuator
extension and
Retraction
Programmable Logic Controller

Hydraulic System Logic module computes the input

Electrical System value of F2 and F4, by interacting
The hydraulic system comprises with the inputs and outputs of the
The electrical system controls the
of the pumping unit, electrical system. It also sends
hydraulic equipment. It interacts
electrohydraulic valves, information to PID controller for
with the PLC, and the hydraulic
actuators pressure reducing feedback and comparison with
system
valves flow control valves, and output.
connectors.

PID Controller
The PID controller compares the
actual output of the actuators with
Linear Variable Displacement the desired input, through
Transducer feedback from the linear variable
differential transducer.

Fig 2. Control Architecture for the Reconfigurable Assembly Fixture

278