Lecture 8

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 1/15
Lecture 8
Lecture 8
Lecture 8
Example – Logic Control of a pick and place Robot
The example of logic control requires careful analysis to avoid

triggering an output at the wrong point in a cycle. The right input
conditions must be used to avoid any conflicts and this is
sometimes known as interlocking. This is required because the
program is executed repeatedly at high speed relative to any of the
mechanical operations and therefore all rungs may be regarded as
executed at once.
Some PLC’s permit the execution of staged programs. In these

cases the program only partially executes and waits for an input
such as a relay signal indicating completion of an operation before
proceeding to the next stage of the program. In this instance the
sequence of the rungs in the program is important.
Lecture 8
In the case of the robot cycle the program would look something
like:
Stage 1
24
Extend Arm
04
Stage 2
23
Lower Arm
03
Stage 3
Stage 12
21
Rotate cw
01
Jump Stage 1
Lecture 8
The stages run sequentially because there is no overlap in the

operations.
Stages may run in parallel if required.
Staged programs are much easier to follow in terms of the logic

and require few inputs to trigger outputs. Hence the debugging is
much simpler than in the case of interlocked programs.
Lecture 8
Advantages of PLC’s
1 Flexibility. If the sequence of events in a process needs to be

changed this can simply be achieved by reprogramming the
software unlike hard wired relays which would have to be
reconfigured.
Also the system can be fine tuned to improve process time

and productivity with ease.
Using modular PLC’s increased complexity can be

accommodated at later stages.
2 Set up. Even before programming the electrician can wire up

inputs and outputs as these can be arbitrarily assigned during
the programming stage.
Debugging and program editing is relatively simple.

Lecture 8
3 Reliability/Maintainability. A PLC uses solid state relays,

therefore there are no moving parts which reduces the
possibility of failure. This is important when one considers
that the program executes millions of times over the lifetime
of the process being controlled.
In the event of a failure it is usually possible to diagnose the

fault by analysing the power flow and verifying the logic.
4 Data collection. PLC’s have the capability of doing counting

operations, quality rejections, machine operation hours etc.
Lecture 8
5 Input/ Output option. PLC’s are ideal for sending pulsed

outputs to drive stepper motors.
PLC’s can also send data to a screen or printer but as

sophistication grows it becomes difficult to distinguish a PLC
from a PC.
6 Cost. For complex systems (>10 relays) the PLC is cheaper

than stand alone relays. Power consumption and floor space is
also less than the hard wired systems for large control
problems.
Lecture 8
Disdvantages/precuations of/with PLC’s
1 Ease of use can lead to a lack of care and analysis in the

design stage prior to programming which can lead to failure
later on.
2 For safety purposes always include a master control relay to

de-energise all PLC outputs at the push of a button i.e., a
mechanically operated switch so that any fault in solid state
electronics can be overridden.
3 Take into account sudden loss of power so that when the

outputs are de-energised the process is in a safe mode.
Lecture 8
PLC Hardware
Input unit
Digital input using a binary signal.
The sensor relay is usually powered by 24V DC although if cable

runs are excessively long then higher voltage AC is used
Lecture 8
PLC Hardware
The signal from the sensor is then filtered using an RC network to

give a low pass filter which removes any transients or noise. Note
that this will also prevent any high frequency signals for which a
special input circuit is employed.
An opto coupler is used to isolate the internal circuitry, this

prevents any voltage spikes from interfering with or damaging the
circuit.
There is also a light emitting diode (LED) associated with each

input indicating its status. Note that a normally closed input will
have its LED illuminated when the input signal has not been
activated
Lecture 8
PLC Hardware
Output Unit
1 Relay
The mechanical relay is prone to wear because of moving

mechanical parts but can switch AC or DC currents up to 2
amps.
Lecture 8
PLC Hardware
2 Transistor
For DC loads up to 1 amp. The switch is unidirectional so

care must be taken with polarity of the DC power supply.
Lecture 8
PLC Hardware
3 Triac
The triac is used for switching AC current up to 1 amp. The filter circuit
minimises the effect of high frequency harmonics due to the switching on
and off of AC voltages. The harmonics would otherwise cause
radiofrequency interference and damage the load.
For high power applications the output of the PLC must drive a further
switching circuit to control devices such as motors, heating elements etc.
Lecture 8
PLC Hardware
Memory Allocation

Lecture 8

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Manufacturing Automation for Assembly and Inspection MM453

Manufacturing Automation for Assembly and

Dr. Nigel Kent

Dublin City University

The example of logic control requires careful analysis to avoid

Some PLC’s permit the execution of staged programs. In these

The stages run sequentially because there is no overlap in the

Stages may run in parallel if required.

Staged programs are much easier to follow in terms of the logic

1 Flexibility. If the sequence of events in a process needs to be

Also the system can be fine tuned to improve process time

Using modular PLC’s increased complexity can be

2 Set up. Even before programming the electrician can wire up

Debugging and program editing is relatively simple.

3 Reliability/Maintainability. A PLC uses solid state relays,

In the event of a failure it is usually possible to diagnose the

4 Data collection. PLC’s have the capability of doing counting

5 Input/ Output option. PLC’s are ideal for sending pulsed

PLC’s can also send data to a screen or printer but as

6 Cost. For complex systems (>10 relays) the PLC is cheaper

1 Ease of use can lead to a lack of care and analysis in the

2 For safety purposes always include a master control relay to

3 Take into account sudden loss of power so that when the

The sensor relay is usually powered by 24V DC although if cable

The signal from the sensor is then filtered using an RC network to

An opto coupler is used to isolate the internal circuitry, this

There is also a light emitting diode (LED) associated with each

The mechanical relay is prone to wear because of moving

For DC loads up to 1 amp. The switch is unidirectional so

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