Mechatronics LAB-4

Name: Yadnesh Chhatre ME-A

Batch-3 Roll no: 61
PRN- 12110342

Introduction: -

A Programmable Logic Controller, which is usually called a PLC or, more commonly, simply
a programmable controller, is a solid-state, digital, industrial computer. Upon first glance, a
programmable controller may seem to be no more than a block box with wires bringing
signals in & wires sending signals out. The PLC is a computer; however, without a set of
instruction telling it what to do, it is nothing more than a box full of electronic components.
The user program is the list of instructions that tells the PLC what to do. Computers such as
PLC’s can be wonderful tools; however, although it might appear otherwise, they only do
exactly what the human programmer told them to do. WHAT IS A PROGRAMMABLE
LOGIC CONTROLLER (PLC)? The programmable logic controller (PLC), or programmable
controller, can be classified as a solid-state member of the computer family. A programmable
controller is an industrial computer in which control devices such as limit switches, push
buttons, proximity or photoelectric sensors, float switches, or pressure switches, to name a
few, provide incoming control signals into the unit. An incoming control signal is called an
Input. Incoming control signals, or inputs, interact with instructions specified in the user
ladder program, which tells the PLC how to react with the incoming signals. The user
program also directs the PLC on how to control field devices like motor starters, pilot lights,
& solenoids. A signal going out of the PLC to control a field device is called an Output.
Figure 1 gives an overview of the interaction between SW 1 (the systems input), the PLC &
its ladder program, & the pilot light output.
A GENERAL OVERVIEW OF PLC IDENTIFYING SW-1, THE PLC INPUTS AND
OUTPUTS A formal definition of a PLC comes from the National Electrical Manufacturers
Association (NEMA): A programmable controller is a digitally operated electronic system,
designed for use in an industrial environment, which uses a programmable memory for the
internal storage of userorientated instructions for implementing specific functions such as
logic sequencing, timing, counting, & arithmetic to control, through digital or analogue inputs
& outputs, various types of machines or processes. Both the PLC & its associated peripherals
are designed so that they can be easily integrated into an industrial control system & easily
used in all their intended functions. WHY USE A PLC? The question, “Why use a PLC?”
really should be rephrased to, “Why automate?” The PLC is a tool that controls an automated
process. What will automating a process do for a company? Automation will help a
manufacturing facility to: 1. Gain complete control of the manufacturing process 2. Achieve
consistency in manufacturing 3. Improve quality & accuracy 4. Work in difficult or hazardous
environments 5. Increase productivity 6. Shorten the time to market 7. Lower the cost of
quality, scrap, & rework 8. Offer greater product variety 9. Quickly change over from one
product to another 10. Control inventory.
PNEUMATIC CONNECTION:
1. Connect AFR pneumatic pipe to Inlet of Air Manifold
2. Connect AIR Manifold pneumatic pipe to port IN of 3/2 Solenoid valve & 5/2 Solenoid Valve
3. Connect Port Out of 3/2 Solenoid valve extracting port IN of single acting cylinder.
4. Connect Port A of 5/2 Solenoid Valve extracting port A of Double acting cylinder
5. Connect Port B of 5/2 Solenoid Valve retracting port B of Double acting cylinder
ELECTRICAL CONNECTION:
• Connect +24VDC & -24VDC on PLC unit to +24VDC & GND test point on Power Supply Unit
• Connect +24V DC to the +24V DC terminal (red) of PS1, PS2, PS3 & PS4
• Connect -24V DC (GND) to the -ve terminal/GND (Black) of PS1, PS2, PS3 & PS4
• Connect O/P (Yellow) of the PS1 to the I1 on PLC Unit
• Connect O/P (Yellow) of the PS2 to the I2 on PLC Unit
• Connect O/P (Yellow) of the PS3 to the I3 on PLC Unit
• Connect O/P (Yellow) of the PS4 to the I4 on PLC Unit
• Connect GND (Black) test point on panel to GND point on 3/2 SV
• Connect GND (Black) test point on panel to GND point on 5/2 SV
• Connect Q1 (Yellow) From PLC panel to +24V DC (red) 3/2 SV.
• Connect Q2 (Yellow) From PLC panel to +24V DC (red) on 5/2 SV respectively.
PROCEDURE (OPERATION OF A+, B+, A- , B-):
1. Connect the compressor to the AFR.
2. Start the compressor, set the desired pressure through the AFR.
3. Do the pneumatic connections as shown above.
4. Plug the trainer supply wire in socket(230VAC,50Hz)
5. Operate Toggle switch I6 (OFF), I7 (OFF) & I8 (ON) on PLC panel.
6. Observe the A+, B+, A-, B- operation of two cylinders by PLC Control method.
7. Vary the air flow through flow control valves mounted on Single Acting Cylinder and Double
acting cylinder for speed control of reciprocating.
Snapshot: