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Discrete Control Logic

1. Pneumatic circuits

- Low forces
- Discrete, fixed travel distances
- Rotational or reciprocating motion

Main components: compressor, valves, cylinders

Pneumatic components: cylinders


double -acting

spring-return

air supply
vent to atmosphere (air discharge

tepping away from this mat, the person has to manually switch the robot back ON

Pneumatic components: valves

a 3/2 valve

a 5/2 valve

valve actuation

return spring

pneumatic

foot pedal

push button

solenoid (electrical)

roller (mechanical)

Simple Pneumatic control


START, A+, A-

Start

A+

A-

VA

Pure Pneumatic control design: Cascade method


Example: Punch Press Operation:
(i) part is clamped in position
(ii) press punches the part
(iii) the clamp is released
(iv) part is removed from the table

START, A+, B+, B-, A-, C+, C-

Functions of A, B, C ?
How to design pneumatic system?

Pure Pneumatic control design: Cascade method


(1) Write cylinder action sequence
(2) Partition sequence into minimum no. of groups (no letter repeated in group)
(3) Merge last group, first group (if possible)
(4) Each cylinder is double-acting
(5) Each cylinder is controlled by 5/2 valve (both pilot lines: pneumatic)
(6) Each + and position of cylinder: limit valves
(7) Each group => manifold line.
The manifold line connects to the limit valves associated with the cylinders.
(8) The air pressure in the manifolds is controlled by 5/2 valves called group valves.
no. of group valves = (no of groups 1)

Cascade method: forming groups


START, A+, B+, B-, A-, C+, CBreak it down into groups:
START, A+, B+ / B-, A-, C+
GRP 1
GRP 2

/ CGRP 3

Merge Group 3 with Group 1 ?


START, A+, B+ / B-, A-, C+
GRP 1 GRP 2

/ CGRP 1

Cascade method: draw cylinders, manifolds, valves

- Draw the cylinders


- For each cylinder, draw the limit valve (3/2 way)
- For each cylinder, draw the control valve
- Draw manifold lines
- Limit valve connections:
a2, b2 and c1 get their air supply from manifold 1
a1, b1 and c2 get their air supply from manifold 2
- Group valve connections:
air supply: initially to GRP 1 (manifold 1), when pilot line 1 is active.
line 1: activated by c2 (transition from GRP 2 GRP 1)
line 2: activated by b2
- Connect air supply of each cylinders valve, and supply + and ports of each cylinder
- Connect the logic lines according to sequence: START A+ B+ B- A- C+ C-

Cascade method: forming groups


-

a1

VA

b1

a2

VB

b2

c1

VC

Start

1
2

Cascade circuit for: START, A+, B+, B-, A-, C+, C-

c2

Pure Pneumatic Controls

- For more complex logic, difficult to debug


- Less versatile than electronic control (e.g. no counters, poor timer control)

- pneumatics timer control: delay valves.

Programmable Logic Controllers

History: avoiding complex/large relay boards


- Why are relay boards required?

PLC Basics:
computer + relays

data communication wire

p
ut

ut

C
A/ 0V
22

inp

0
ut

u
i np

ut
i np
t1

3
ut
i np

inp

4
ut

u
inp

i np
t5

Box with
Computer
(controller)
Power supply wire

6
ut

PLC: example 1

Pressure_Switch is ON Warning_Light ON

PLC: example 1

STEP 1:
Write this logic into a PROGRAM
STEP 2:
Load program into PLC
STEP 3:
Connect the sensor output to External Input terminal.
STEP 4:
Connect the PLC External Output Terminal to Warning Light
STEP 5:
EXECUTE the logic program on the PLC.

PLC: example 1

Programming language: LADDER LOGIC

PLC: example 1

Programming language: LADDER LOGIC

IF

THEN

PLC: example 2

Outer mat ON warning light ON


Inner mat ON warning light ON AND

Robot OFF

Stepping away from inner mat Manually switch robot ON

PLC: example 2
Two actuators: Warning light, Robot master switch
LOGIC for Warning light
External Input 1: outer mat

External Input 2: inner mat

External output: light

PLC: example 2

LOGIC for Warning Light

LOGIC for Robot

PROBLEM ?

PLC: example 2
LOGIC for Robot
Robot must STAY OFF until manual reset to ON
Solution: LATCH
External Input 2: inner mat

Internal (logical) relay

latch

External output: robot

PLC: example 2
LOGIC for Robot
Robot must STAY OFF until manual reset to ON

Ladder Logic Programs

Switch (Relay) naming conventions


Lecture notes (Rockwell Automation PLC):
External inputs: I:0/1, I:0/2, , I:1/1, I:1/2, I:n/m
External outputs: O:0/1, O:0/2, , O:1/1, O:1/2, O:n/m
Internal Relays: B0, B1,
etc.
Lab (SMC PLC):
External inputs: X0, X1,
External outputs: Y0, Y1, ,
Internal Relays: R0, R1,
etc.

PLC Example: XOR Logic

A xor B:
(A is ON AND B is OFF) OR (A is OFF AND B is ON)

Ladder Logic: Timers


Solenoid actuated door-lock

Solenoid ON Door unlocked

Solenoid actuated when:


(i) ON signal from number-pad outside door
(ii) ON signal from door-open switch inside door
Solenoid ON for 5 sec, then OFF

While O:0/1 remains ON,


Timer COUNTS DOWN from PRESET
COUNT DOWN = 0 ( T4:1) set to ON

Ladder Logic: Timers


Solenoid actuated door-lock

Solenoid ON Door unlocked

Solenoid actuated when:


(i) ON signal from number-pad outside door
(ii) ON signal from door-open switch inside door
Solenoid ON for 5 sec, then OFF

Ladder Logic: Timers -- reset


Solenoid actuated when:
(i) ON signal from number pad outside door
(ii) ON signal from door-open switch inside door
Solenoid ON for 5 sec, then OFF

During ON, if button is pressed,


Timer resets to PRESET
During ON, light indicator is ON

LEGEND:
I:0/1 door-open
I:O/2 card-reader
O:0/1 solenoid
O:0/2 light indicator

Ladder Logic: counters


Count the number of occurrences of an event

Examples:
Pallet loading in factory
After 10 parts arrive on conveyor, worker comes to load pallet

Pneumatic press hammer


Hit the part 20 times, then wait for part to be unloaded
Rice cooker alarm
Beep 5 times when rice is cooked

EVENT: switch goes from OFF ON

Ladder Logic: counters


Pallet loading in factory

After 4 parts arrive on conveyor:


STOP conveyor belt
turn ON the indicator light

Ladder Logic: car wash

Car arrives limit switch ON


Limit switch ON Washer ON
Washer ON:
(i) Soapy water SPRAY ON (30 secs)
(ii) Rinse: clean water SPRAY ON (30 secs)
(iii) Automatic scrubber brushes car (15 secs)
(iv) After washing 50 cars, the scrubber brush Auto-change

I:0/1

B1

I:0/2

B1
T4: 0
EN
Base:
Preset:
Accum :

0.01
3000
0

B1
T4: 1
EN
Base:
Preset:
Accum :

B1

0.01
6000
0
T4: 2
EN

Base:
Preset:
Accum :
B1

T4:1

T4:0

0.01
7500
0
T4:2

B1

DN
DN
T4:0 T4:1

DN
T4:2

B1

DN
DN
T4:0 T4:1

DN
T4:2

DN

DN

I:0/1 : System On
I:0/2 : Em ergency Stop
I:0/3 : Lim it Switch
O:0/0
O:0/1
O:0/2
O:0/3

:
:
:
:

Soa p Water On
Rinse On
Scrubber On
Ac tivate Scrubber Change

Notice how B1 and the time r outputs are


used to c ontrol the logic
according to the required timing.

O:0/0

O:0/1

O:0/2

DN

O:0/2
CTU

C5: 0
EN

Preset:
Accum :
C5: 0
DN
I:0/3

50
0
O:0/3

T4:0
RES

I:0/3

T4:1
RES

I:0/3

T4:2
RES

O:0/3

C5:0
RES

Car arrives limit switch ON


Limit switch ON Washer ON
Washer ON:
(i) Soapy water SPRAY ON (30 secs)
(ii) Rinse: clean water SPRAY ON (30 secs)
(iii) Automatic scrubber brushes car (15 secs)
(iv) After washing 50 cars, the scrubber brush Auto-change

Programming a PLC

(1) Hand held console (direct feed of program into PLC)

(2) Computer-interface:
(i) Complete the program on a computer
(ii) Test the program on PC
(iii) Upload the program to the PLC processor memory (persistent)
(iv) Connect external Inputs and Outputs
(v) Run the program on PLC

Operation cycle of PLC


Phase 2

Phase 1

Phase 3

00

00

01

Program
Memory

02

30

30

03

31

04

32
33

05

Processor

06

34

07

35

08

36

Accumulator
09
10
11

11

input

input
register

37

37

output
register

output

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