Lecture6

Manufacturing Automation for Assembly and Inspection MM453
Manufacturing Automation for Assembly and

Inspection
MM453
Dr. Nigel Kent

Rm S366
nigel.kent@dcu.ie
Dublin City University
Sem 1 2021
Dr. Nigel Kent Manufacturing Automation for Assembly and Inspection, MM453 1/14
Lecture 6
Lecture 6
Lecture 6
Programmable Logic Controllers (PLCs)
PLCs are one of the most commonly used controllers in

automation.
Lecture 6
Siemens S7 1200 PLCs as used in this course.
Lecture 6
• PLC’s are microprocessor based and therefore similar in many

respects to a PC. The obvious difference is that there is no
permanent screen and keyboard.
• These are only connected during the programming stage.
• A single relatively small program is stored in memory and
executed repeatedly when the PLC is in operation.
• The PLC functions by scanning the inputs from a set of
sensors and evaluating their logical relationships to the defined
outputs such as actuators, relays etc. according to the
programmed logic.
Lecture 6
• By comparison with the response time of the mechanical

system controlled by the PLC, the execution of the program is
of the order of milliseconds and therefore the individual rungs
may be considered to execute simultaneously.
• If the inputs change during the processing interval this will
not usually cause a problem as the following program
execution will occur within a fraction of a second and will take
into account the new input configuration.
Lecture 6
There are two methods of programming a PLC.

Logic Control
On completion of each step in the process a sensor is switched
which changes one of the inputs to the PLC. The PLC processes
the new inputs and changes the outputs appropriately. This
requires feedback from the sensors and is a closed loop approach.
Sequencing
In this case internal timers in the PLC are used to calculate the
completion time of the present step and hence trigger the next
step. This is open loop control.
Lecture 6
• Sequencing does not require feedback sensors, but it is not as

efficient as logic control.
• In logic control each step only takes the minimum time
required unlike sequencing where some safety margin is
necessary.
• Logic control assures completion of the preceding step before
moving to the next stage.
• As well as monitoring inputs and setting outputs, many PLC’s
have added functions such as timing, counting, a/d conversion
etc. Each type of PLC will have its own special features, the
details of which are obtained from the operating and
programming manual.
Lecture 6
Example – Sequence control of a machine tool
A work piece is loaded onto a machine tool, machined and then

unloaded, involving 8 operations A-H. These are examined using a
Multiple Activity Chart also known as a Cycle Layout.
Task
A
Load
B
Clamp
C
Coolant On
D
Spindle On
E
Tool Advance
F
Machine
G
Tool Retract
H
Unload
1 2 3 4 5 6 7 8 9 10 11 12 13
Lecture 6
In terms of sequence programming a new step is identified every

time something changes i.e. one or more activities either begin or
end.
The operations A-H are set by the PLC and connected to the
outputs. The sequence is organised into steps using a matrix.
Step Time (s) A B C D E F G H

1 2 1 0 0 0 0 0 0 0
2 1 0 1 1 0 0 0 0 0
3 2 0 1 1 1 1 0 0 0
4 4 0 1 1 1 0 1 0 0
5 1 0 1 1 1 0 0 1 0
6 1 0 1 0 0 0 0 0 0
7 2 0 0 0 0 0 0 0 1
Lecture 6
To program the above we could do the following.

Use a register, ’Op Ctrl.Steps’ to indicate which step we are on.
The step number then corresponds with which bit of the register is
switched on.
The bits are numbered 0,1,2,3 etc. So for step two, bit number 1
can be set using Op Ctrl.Steps%X1 = 1 and all other bits set to
off.
Op Ctrl.Steps
X7 X6 X5 X4 X3 X2 X1 X0
0 0 0 0 0 0 0 1 → Step 1
0 0 0 0 0 0 1 0 → Step 2
0 0 0 0 0 1 0 0 → Step 3
Lecture 6
Example – Sequence control of a machine tool - Siemens Specific
Shift Function
If "Shift"."Shift cmd" contact is set high or energised then the

bits of the register Op Ctrl.Steps are shifted 1 place to the left.
Lecture 6
Controlling the second step of the sequential machining operation
If "Shift"."Shift cmd" contact is set high or energised then the

bits of the register Op Ctrl.Steps are shifted 1 place to the left.
For Step 2, "Step1 Tim 1s" goes high after 1 second.

"Shift"."Shift cmd" will then go high at which point the 1 in
the register will move to Op Ctrl.Steps%X2 for the third step.
Lecture 6
Switching on the outputs for step 2
During step 2 (Op Ctrl.Steps%X2 is on), Outputs for tasks B

and C, ’Clamping’ and ’Coolant on’, are on for 1 second.

Lecture6

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Manufacturing Automation for Assembly and Inspection MM453

Manufacturing Automation for Assembly and

Dr. Nigel Kent

Dublin City University

PLCs are one of the most commonly used controllers in

Siemens S7 1200 PLCs as used in this course.

• PLC’s are microprocessor based and therefore similar in many

• By comparison with the response time of the mechanical

There are two methods of programming a PLC.

• Sequencing does not require feedback sensors, but it is not as

A work piece is loaded onto a machine tool, machined and then

In terms of sequence programming a new step is identified every

Step Time (s) A B C D E F G H

To program the above we could do the following.

If "Shift"."Shift cmd" contact is set high or energised then the

Controlling the second step of the sequential machining operation

If "Shift"."Shift cmd" contact is set high or energised then the

For Step 2, "Step1 Tim 1s" goes high after 1 second.

Switching on the outputs for step 2

During step 2 (Op Ctrl.Steps%X2 is on), Outputs for tasks B

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