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![]() You’re cruising in your brand new Ford Pinto on the way to your job at the local Rubik’s Cube plant. The Origins of Ladder Logic – Relay Logic ![]() Different types of programming languages have also been developed for PLCs but the most frequently used is still Ladder Logic. Over time they have advanced to become more user friendly, efficient, smaller and less expensive. To get this free article, subscribe to my free email newsletter.PLCs have exploded in the controls market and are used throughout the world. This includes Bits, Decimal, Hexadecimal, ASCII and Floating Point. We will walk through the numbering systems used in PLCs. Numbering systems used in PLC’s are not difficult to learn and understand. If you’re like most of my readers, you’re committed to learning about technology. If you have any questions or need further information please contact me. ![]() Watch on YouTube: Process Mixer Test Simulation Watch the following video to see this simulation in action. You can download the PLC program and Factory IO scene here. Start at the ‘Getting Started’ at the following URL: Here is the mapping of the inputs and outputs using Factory IO.įactory IO Website is at the following URL:ĭocumentation is well done. When the tank fills up we will start a dwell time instead of the mixer time for the simulation. Factory IO will be the Modbus TCP Client (Master). We will be using the BRX PLC Modbus TCP Server (Slave). Factory IO provides a straight forward method of seeing your program in action before you wire your application. Testing of the program is important and should be done in a variety of ways. Watch on YouTube: PLC Programming Example – Process Mixerįactory IO provides a 3D simulation of the process. The result will be a better-defined logic and easier to understand the program, because it has within the documentation the logic flow chart or sequence table. Using this five-step to program development technique will shorten your programming time. Check to see what happens when power is removed. Simulate the PLC program of the Process Mixer It will reset when the empty sensor switch goes off. Solenoid B turns on to empty the tank when the timer is done and the full and empty sensors are on. Mixing motor will be on when the timer is timing and when the timer is not done. The timer will reset when the empty and fill sensors are off. The memory retentive timer will start timing when we have the start sequence signal and when the empty and fill sensors are on. (Sequence Table) You will notice that we have a memory retentive output and the actual output to active the solenoid. It is turned on by the start signal and off by the full sensor switch. The filling of the tank is done through Solenoid A. From the sequence table, we know that to reset the sequence we need to have the timer done and the empty sensor off. The first thing in our program is to control the start and stop functions. In our example, we will use the ‘V Memory’ locations. Since we need to continue the sequence when the power goes off then memory retentive locations in the PLC must be used. Writing the PLC sample ladder logic program for the process mixer. Knowing all of these answers upfront is vital in the development of the PLC program. It will help prevent you from continuously re-writing the PLC logic. This is the step where you can save yourself a lot of work by understanding everything about the operation. What happens when electrical power and/or pneumatic air is lost? What happens when the input / output devices fail? Do we need redundancy? It will also prompt questions like the following. How the PLC example program is to solve the logic.Ī flow chart or sequence table is used to fully understand the process. Timer 3 minutes – (Internal) 3 – Develop a logical sequence of operation: Timer 3 minutes done bit – On/Off (Internal) Stop Pushbutton – Normally Closed – On/Off Start Pushbutton – Normally Open – On/Off What sensors will be used in the PLC program? The start button is pressed to repeat the sequence. When the tank is completely empty, the empty sensor switch opens to de-energize solenoid B. When the agitate motor stops, solenoid B is energized to empty the tank. The mixer motor starts and runs for 3 minutes to mix the liquid. When the tank is full, the full-level sensor switch closes. As the tank fills, the empty level sensor switch closes. ![]() When the start button is pressed, solenoid A energizes to start filling the tank. 1 – Define the task:Ī normally open start and normally closed stop pushbuttons are used to start and stop the process. We will discuss each step of the PLC program development. ![]() The process mixer will be programmed using ladder logic. 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