R01_MainRoutine - Ladder Diagram Page 1

ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:18 PM

Total number of rungs in routine: 9 G:\PROJECT\plc project 2\Project2Template.ACD

*********************************************************************
For Simulation - Leave this at the top of the program and
Do Not Delete this rung!
*********************************************************************
JSR
0 Jump To Subroutine
Routine Name R99_Simulate

Start Light Turns ON when MCR is on start PB is pressed and turns off when Stop PB is pressed.
MCR ON Start PB Stop PB Start Light
I2.5 I2.0 I2.1 O3.0
<Local:2:I.Data.5> <Local:2:I.Data.0> <Local:2:I.Data.1> <Local:3:O.Data.0>
1
Start Light
O3.0
<Local:3:O.Data.0>

Routine R08_Ramp is connected with ramp properties. This JSR instruction used to jump from the main routine to the R08_Ramp
JSR
2 Jump To Subroutine
Routine Name R08_Ramp

indication and elimination info for Faults related to Cylinder's extension and retraction is stored at this routine.This JSR instruction is used to
jump to the R06_CylinderFaults routine from the main routine.
JSR
3 Jump To Subroutine
Routine Name R06_PartStopSecureFaults

Conveyor runs only when start light is on and pbb light is off. PBB light turns on when the ramp is full for certain fixed time.
Start Light PBB Light Conv Run
O3.0 O3.3 O51.0
<Local:3:O.Data.0> <Local:3:O.Data.3> TP.PLC.GRAY.LT <Ethernet5_WAGOIO:O.Data[1].0>
4 /

this JSR rung is used to jump to R02_StationStamp from Main Routine

JSR
5 Jump To Subroutine
Routine Name R02_StampStation

this JSR rung is used to jump R03_TransferStation into Main Routine

JSR
6 Jump To Subroutine
Routine Name R03_TransferStation

False sensor trigger routine is to provide indication and elimination if the sensor is off for certain time. This JSR instruction is used to jump to
the R04_FalseSensorTrigger routine from the main routine.
JSR
7 Jump To Subroutine
Routine Name R04_FalseSensorTrigger

Logix Designer
R01_MainRoutine - Ladder Diagram Page 2
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:25 PM
Total number of rungs in routine: 9 G:\PROJECT\plc project 2\Project2Template.ACD

This routine is used to identify the properties related to part. it calculates the cycle time, count the total no. of part that are stamped and gives
indication if the part on conveyor is taking more time (Cycle is slow) or more parts are done than the required.
Part Counting and
Cycle Time
JSR
8 Jump To Subroutine
Routine Name R05_PartTimingCountng

(End)

Logix Designer
R02_StampStation - Ladder Diagram Page 3
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:26 PM
Total number of rungs in routine: 14 G:\PROJECT\plc project 2\Project2Template.ACD

Stamp Lower Solenoid turns on when start light is on, Stamp secure solenoid is extended and it turns off if the Green Light is ON.
Part At Stamp Stamp Secure Extend Stamp Lower
I50.2 O50.3 O50.1
<Ethernet5_WAGOIO:I.Data[0].2> <Ethernet5_WAGOIO:O.Data[0].3> TP.PLC.GREEN.LT <Ethernet5_WAGOIO:O.Data[0].1>
0 /
Stamp Lower
O50.1
<Ethernet5_WAGOIO:O.Data[0].1>

Green Light turns ON when Yellow TP Light is on ( jump from R04_FalseSenserTrigger Routine ), CH0 ( stamp pressure) is greater than 7.5.
and it turns of when part reaches at transfer
Part At Transfer
I50.7
TP.PLC.YELLOW.LT GRT <Ethernet5_WAGOIO:I.Data[0].7> TP.PLC.GREEN.LT
1 Greater Than (A>B) /
Source A CH0
<Local:4:I.Ch0Data>
0.02
Source B 7.5

TP.PLC.GREEN.LT

This JSR instruction is used to jump from this routine to the R07_StampPressure sub routine to mcalculate the value of Result Pressure in Psi
JSR
2 Jump To Subroutine
Routine Name R07_StampPressure
Input Par CH0
<Local:4:I.Ch0Data>
Input Par 200.9
Input Par 20.9
Return Par R07_ResultPressurePsi

When Stamp Lowered Sensor is on, R02_ResultPressurePsi's is moved to the TP.PLC.REAL4 (pressure of current stamp)
Stamp Lowered
I50.1
<Ethernet5_WAGOIO:I.Data[0].1> MOV
3 Move
Source R07_ResultPressurePsi
21.26
Dest TP.PLC.REAL4
159.036

Logix Designer
R02_StampStation - Ladder Diagram Page 4
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:26 PM
Total number of rungs in routine: 14 G:\PROJECT\plc project 2\Project2Template.ACD

Part Stop Extension Solenoid turns on when start light is on, Part is at Stamp or stamp is on raised or part is at transfer or Transfer is retracted
and it turns off when green light is off.

Start Light Part At Stamp

O3.0 I50.2
<Local:3:O.Data.0> <Ethernet5_WAGOIO:I.Data[0].2> TP.PLC.GREEN.LT
4 /
Part Stop Extend Stamp Raised
O50.2 I50.0
<Ethernet5_WAGOIO:O.Data[0].2> <Ethernet5_WAGOIO:I.Data[0].0>
/
Part At Transfer
I50.7
<Ethernet5_WAGOIO:I.Data[0].7>

Transfer Retracted
I50.6
<Ethernet5_WAGOIO:I.Data[0].6>
/

Part Stop Extend

O50.2
<Ethernet5_WAGOIO:O.Data[0].2>

Stamp Secure Extension Solenoid turns on when start light is on, Part is at stamp, Part stop extension solenoid is on or stamp lower sensor is
off.

Start Light Part At Stamp Part Stop Extend

O3.0 I50.2 O50.2
<Local:3:O.Data.0> <Ethernet5_WAGOIO:I.Data[0].2> <Ethernet5_WAGOIO:O.Data[0].2>
5
Stamp Secure Extend Stamp Lowered
O50.3 I50.1
<Ethernet5_WAGOIO:O.Data[0].3> <Ethernet5_WAGOIO:I.Data[0].1>
/

Stamp Secure Extend

O50.3
<Ethernet5_WAGOIO:O.Data[0].3>

Stamp Raise Solenoid turns on when Start light is on, Stamp lower sensor is on and Green Light is on.
Start Light Stamp Lowered Raise Stamp
O3.0 I50.1 O50.0
<Local:3:O.Data.0> <Ethernet5_WAGOIO:I.Data[0].1> TP.PLC.GREEN.LT <Ethernet5_WAGOIO:O.Data[0].0>
6

When Stamp is lowered and Part Count.Acc is Equal to 1, Then TP.PLC.REAL4 (Current stamp pressure) value is moved to
FirstStampPressure Tag'
Stamp Lowered
I50.1
<Ethernet5_WAGOIO:I.Data[0].1> EQU MOV
7 Equal Move
Source A PartCount.ACC Source TP.PLC.REAL4
0 159.036
Source B 1 Dest FirstPartStampPressure
156.20581

Logix Designer
R02_StampStation - Ladder Diagram Page 5
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:26 PM
Total number of rungs in routine: 14 G:\PROJECT\plc project 2\Project2Template.ACD

When Stamp is lowered and Part Count.Acc is Equal to 2, Then TP.PLC.REAL4 (Current stamp pressure) value is moved to
SecondStampPressure Tag'
Stamp Lowered
I50.1
<Ethernet5_WAGOIO:I.Data[0].1> EQU MOV
8 Equal Move
Source A PartCount.ACC Source TP.PLC.REAL4
0 159.036
Source B 2 Dest SecondStampPressure
161.04826

When Stamp is lowered and Part Count.Acc is Equal to 3, Then TP.PLC.REAL4 (Current stamp pressure) value is moved to
ThirdStampPressure Tag'
Stamp Lowered
I50.1
<Ethernet5_WAGOIO:I.Data[0].1> EQU MOV
9 Equal Move
Source A PartCount.ACC Source TP.PLC.REAL4
0 159.036
Source B 3 Dest ThirdStampPressure
156.3069

This instruction Added the FirstStampPressure and SecondStampPressure and saves the value at FirstTwoPressureSum Tag( StampPressure
of First two stamps in Psi)
ADD
10 Add
Source A FirstPartStampPressure
156.20581
Source B SecondStampPressure
161.04826
Dest FirstTwoPressureSum
317.2541

This instruction Added the First Two Stam Pressur eSum and third Stamp Pressure and saves the value at FirstThreePressureSum Tag(
StampPressure of First three stamps in Psi)
ADD
11 Add
Source A FirstTwoPressureSum
317.2541
Source B ThirdStampPressure
156.3069
Dest FirstThreePressureSum
473.56097

if the PartCount.ACC is greater than 3, the value at FirstThreePressureSum Tag (Sum of first three stamp pressures in Psi ) is divided by 3 and
is placed at TP.PLC.REAL3 (Average of first three stamp pressures)
GRT DIV
12 Greater Than (A>B) Divide
Source A PartCount.ACC Source A FirstThreePressureSum
0 473.56097
Source B 3 Source B 3

Dest TP.PLC.REAL3
0.0

Logix Designer
R02_StampStation - Ladder Diagram Page 6
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:26 PM
Total number of rungs in routine: 14 G:\PROJECT\plc project 2\Project2Template.ACD

if the PartCount.ACC is less than 3, thevalue is cleared to zero for TP.PLC.REAL3 (Average of first three stamp pressures)
LES CLR
13 Less Than (A<B) Clear
Source A PartCount.ACC Dest TP.PLC.REAL3
0 0.0
Source B 3

(End)

Logix Designer
R03_TransferStation - Ladder Diagram Page 7
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:27 PM
Total number of rungs in routine: 4 G:\PROJECT\plc project 2\Project2Template.ACD

Transfer cylinder extension solenoid turns on when the start light is on, Part is at transfer, Ramp is not Full and it retracts when Transfer
extension sensor turns on.

Start Light Part At Transfer Ramp Is Full Tranfer Extended

O3.0 I50.7 I51.0 I50.5
<Local:3:O.Data.0> <Ethernet5_WAGOIO:I.Data[0].7> <Ethernet5_WAGOIO:I.Data[1].0> <Ethernet5_WAGOIO:I.Data[0].5>
0 / /
Extend Transfer
O50.5
<Ethernet5_WAGOIO:O.Data[0].5>

Extend Transfer
O50.5
<Ethernet5_WAGOIO:O.Data[0].5>

TransferCylinderTimer turns on when the part reaches at Transfer.

Part At Transfer
I50.7
<Ethernet5_WAGOIO:I.Data[0].7> TON
1 Timer On Delay EN
Timer TransferCylinderTimer
Preset 6000 DN
Accum 0

RED TP light turns on if the Transfer cylinder timer is done and Transfer cylinder is not extended.
Tranfer Extended
I50.5
TransferCylinderTimer.DN <Ethernet5_WAGOIO:I.Data[0].5> TP.PLC.RED.LT
2 /

Transfer Cylinder Retraction Solenoid turns on when start Light is on, Transfer cylinder extension sensor is on and it turns off if Transfer
cylinder Retraction sensor is on.
Start Light Tranfer Extended Transfer Retracted Retract Transfer
O3.0 I50.5 I50.6 O50.6
<Local:3:O.Data.0> <Ethernet5_WAGOIO:I.Data[0].5> <Ethernet5_WAGOIO:I.Data[0].6> <Ethernet5_WAGOIO:O.Data[0].6>
3 /
Retract Transfer
O50.6
<Ethernet5_WAGOIO:O.Data[0].6>

(End)

Logix Designer
R04_FalseSensorTrigger - Ladder Diagram Page 8
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:28 PM
Total number of rungs in routine: 3 G:\PROJECT\plc project 2\Project2Template.ACD

SensorTriggerTimer starts for certain time when the part is at stamp.

Part At Stamp
I50.2
<Ethernet5_WAGOIO:I.Data[0].2> TON
0 Timer On Delay EN
Timer SensorTriggerTimer
Preset 2000 DN
Accum 0

yellow light turns on when the SensorTriggerTimer.ACC is greater than or equal to 1000. so the Part at stamp sensor should be on for this
certain time otherwise yellow TP light will not turn on and the process will stop there.
GEQ TP.PLC.YELLOW.LT
1 Grtr Than or Eql (A>=B)
Source A SensorTriggerTimer.ACC
0
Source B 1000

This JSR instruction is used to jump from this rung to R02_StampStation where Yellow TP light is used.
JSR
2 Jump To Subroutine
Routine Name R02_StampStation

(End)

Logix Designer
R05_PartTimingCountng - Ladder Diagram Page 9
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:29 PM
Total number of rungs in routine: 16 G:\PROJECT\plc project 2\Project2Template.ACD

Retentive Timer is used to calculate the Cycle Time

RTO
0 Retentive Timer On EN
Timer CycleTime
Preset 99999999 DN
Accum 3363670

Cycle Time is divided by 1000 to give the value in Seconds.

DIV
1 Divide
Source A CycleTime.ACC
3363670
Source B 1000

Dest TP.PLC.REAL1
3363.67

CycleTime is Reset when Transfer Cylinder extension sensor turns on for a while.
Tranfer Extended
I50.5
<Ethernet5_WAGOIO:I.Data[0].5> TestBit CycleTime
2 ONS RES

When the PartCount.ACC is equal to 1, CycleTime.ACC's value is moved to FirstCycleTime tag.

EQU MOV
3 Equal Move
Source A PartCount.ACC Source CycleTime.ACC
0 3363670
Source B 1 Dest FirstCycleTime
5141.0

When the PartCount.ACC is equal to 2, CycleTime.ACC's value is moved to SecondCycleTime tag.

EQU MOV
4 Equal Move
Source A PartCount.ACC Source CycleTime.ACC
0 3363670
Source B 2 Dest SecondCycleTime
3421.0

When the PartCount.ACC is equal to 3, CycleTime.ACC's value is moved to ThirdCycleTime tag.

EQU MOV
5 Equal Move
Source A PartCount.ACC Source CycleTime.ACC
0 3363670
Source B 3 Dest ThirdCycleTime
5200.0

When the PartCount.ACC is equal to 4, CycleTime.ACC's value is moved to FourthCycleTime tag.

EQU MOV
6 Equal Move
Source A PartCount.ACC Source CycleTime.ACC
0 3363670
Source B 4 Dest FourthCycleTime
0.0

Logix Designer
R05_PartTimingCountng - Ladder Diagram Page 10
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:29 PM
Total number of rungs in routine: 16 G:\PROJECT\plc project 2\Project2Template.ACD

When the PartCount.ACC is equal to 5, CycleTime.ACC's value is moved to FifthCycleTime tag.

EQU MOV
7 Equal Move
Source A PartCount.ACC Source CycleTime.ACC
0 3363670
Source B 5 Dest FifthCycleTime
3440.0

When the PartCount.ACC is equal to 6, CycleTime.ACC's value is moved to SixthCycleTime tag.

EQU MOV
8 Equal Move
Source A PartCount.ACC Source CycleTime.ACC
0 3363670
Source B 6 Dest SixthCycleTime
3460.0

When the PartCount.ACC is greater than 6, Compute is used to get average of first six part cycles average. The result is stored at TP.PLC.REAL
GRT CPT
9 Greater Than (A>B) Compute
Source A PartCount.ACC Dest
0
Source B 6 Expression ( FirstCycleTime + SecondCycleTime + ThirdCycleTime + FourthCycleTime + FifthCycleT

( Average time of first six cycles)

TP.PLC.REAL2
0.0
me + SixthCycleTime ) / 6000

if the PartCount.ACC is less than 6, the value gets cleared at TP.PLC.REAL2 ( average time of first six cycles)
LES CLR
10 Less Than (A<B) Clear
Source A PartCount.ACC Dest TP.PLC.REAL2
0 0.0
Source B 6

Part count up by 1 when part passes in front of transfer sensor.

Part At Transfer
I50.7
<Ethernet5_WAGOIO:I.Data[0].7> CTU
11 Count Up CU
Counter PartCount
Preset 6 DN
Accum 0

TP.PLC.INT1 (Part Target) value is moved to PartCount.PRE to set the Parts Target.
MOV
12 Move
Source TP.PLC.INT1
6
Dest PartCount.PRE
6

Logix Designer
R05_PartTimingCountng - Ladder Diagram Page 11
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:29 PM
Total number of rungs in routine: 16 G:\PROJECT\plc project 2\Project2Template.ACD

PartCount.ACC value is moved to TP.PLC.INT2 ( numper of parts done) .

MOV
13 Move
Source PartCount.ACC
0
Dest TP.PLC.INT2
0

TP Blue light turns on when the PartCount.ACC becomes greater than the PartCount.Pre that means when Number of parts Done Exceeds
than the Part Target.
GRT TP.PLC.BLUE.LT
14 Greater Than (A>B)
Source A PartCount.ACC
0
Source B PartCount.PRE
6

TP Blue Button( Parts Done Reset) Reset the PartCount

TP.PLC.BLUE.PB PartCount
15 RES

(End)

Logix Designer
R06_PartStopSecureFaults - Ladder Diagram Page 12
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:30 PM
Total number of rungs in routine: 3 G:\PROJECT\plc project 2\Project2Template.ACD

If the Stamp Secure extension sensor is off or part stop extension solenoid is off or stamp lowered sensor is off but part is present at Stamp,
then PartStopSecureFaultTimer turns on.
PartStopSecureFault
timer is to indicate
the fault occured in
Part stop Solenoid,
Stamp Secure
Extension Solenoid
Secure Extended Part At Stamp or Stamp Lower
I50.3 I50.2 Solenoid.
<Ethernet5_WAGOIO:I.Data[0].3> <Ethernet5_WAGOIO:I.Data[0].2> TON
0 / Timer On Delay EN
Timer PartStopSecureFaultTimer
Part Stop Extend
Preset 5000 DN
O50.2
Accum 0
<Ethernet5_WAGOIO:O.Data[0].2>
/
Stamp Lowered
I50.1
<Ethernet5_WAGOIO:I.Data[0].1>
/

If the PartStopSecureFaultTimer is Done then Gray Tp light turns on means there is Stop solenoid, Stamp Secure solenoid, Stamp Lower
Sensor Fault is present.gray TP light stops the conveyor.
PartStopSecureFault
timer is to indicate
the fault occured in
Part stop Solenoid,
Stamp Secure
Extension Solenoid
or Stamp Lower
Solenoid.
PartStopSecureFaultTimer.DN TP.PLC.GRAY.LT
1

TP Gray PB Resets the PartStopSecureFault TIMER, which starts the conveyor again.
PartStopSecureFault
timer is to indicate
the fault occured in
Part stop Solenoid,
Stamp Secure
Extension Solenoid
or Stamp Lower
Solenoid.
TP.PLC.GRAY.PB PartStopSecureFaultTimer
2 / RES

(End)

Logix Designer
R07_StampPressure - Ladder Diagram Page 13
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:31 PM
Total number of rungs in routine: 2 G:\PROJECT\plc project 2\Project2Template.ACD

R07_StampPressure sub routine has the main formula to convert the stamp pressure value from vol to Psi. the Three input parameters are
SourceStampPressure ( CH0 ), Maximum Pressure, Minimum Pressure and the Result (stamp pressure in psi) is stored in
R07_ResultPressurePsi Tag.

SBR
0 Subroutine
Input Par SourceStampPressure
Input Par MaximumPressure
Input Par MinPressure

CPT
Compute
Dest R07_ResultPressurePsi
21.26
Expression SourceStampPressure / 10 * ( MaximumPressure - MinPressure ) + MinPressure

the return parameter for result value in PSI R07_ResultPressurePsi

RET
1 Return from Subroutine
Return Par R07_ResultPressurePsi

(End)

Logix Designer
R08_Ramp - Ladder Diagram Page 14
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:31 PM
Total number of rungs in routine: 3 G:\PROJECT\plc project 2\Project2Template.ACD

Off Delay Timer Turns on when the Ramp is Full

Ramp Is Full
I51.0
<Ethernet5_WAGOIO:I.Data[1].0> TOF
0 / Timer Off Delay EN
Timer RampFullTimer
Preset 4000 DN
Accum 0

if the RampFullTimer is done, means if the ramp is full for quite a certain pre-decided long period then PBB LIGHT turns on whcich stops the
conveyor.
PBB Light
O3.3
RampFullTimer.DN <Local:3:O.Data.3>
1

Full Button B PBB is used to reset the RampFullTimer to start the process again.
PBB
I2.3
<Local:2:I.Data.3> RampFullTimer
2 RES

(End)

Logix Designer
R99_Simulate - Ladder Diagram Page 15
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:32 PM
Total number of rungs in routine: 31 G:\PROJECT\plc project 2\Project2Template.ACD

SIM_5sPulse.DN MOV TON

0 / Move Timer On Delay EN
Source 5000 Timer SIM_5sPulse
Preset 5000 DN
Dest SIM_5sPulse.PRE Accum 1807
5000

MCR ON
I2.6 I2.7 I2.5
SIM_PowerONPB <Local:2:I.Data.6> <Local:2:I.Data.7> <Local:2:I.Data.5>
1
MCR ON
I2.5
<Local:2:I.Data.5>

LEQ MOV
2 Less Than or Eql (A<=B) Move
Source A SIM_Stamp.Max Source 500
500
Source B 0 Dest SIM_Stamp.Max
500

LEQ MOV
Less Than or Eql (A<=B) Move
Source A SIM_Secure.Max Source 500
500
Source B 0 Dest SIM_Secure.Max
500

LEQ MOV
Less Than or Eql (A<=B) Move
Source A SIM_Transfer.Max Source 1000
1000
Source B 0 Dest SIM_Transfer.Max
1000

MOV
Move
Source 0

Dest SIM_Zero
0

--------------------------------------------
Stamp Sensor Simulation
--------------------------------------------
MCR ON Stamp Lower
I2.5 O50.1
<Local:2:I.Data.5> <Ethernet5_WAGOIO:O.Data[0].1> SIM_Stamp.Extend_Output
3
Raise Stamp
O50.0
<Ethernet5_WAGOIO:O.Data[0].0> SIM_Stamp.Retract_Output

Logix Designer
R99_Simulate - Ladder Diagram Page 16
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:32 PM
Total number of rungs in routine: 31 G:\PROJECT\plc project 2\Project2Template.ACD

SIM_Stamp.Extend_Output LES
4 Less Than (A<B)
Source A SIM_Stamp.Extend_ScanCount
0
Source B 10

ADD
Add
Source A SIM_Stamp.Extend_ScanCount
0
Source B 1

Dest SIM_Stamp.Extend_ScanCount
0

SIM_Stamp.Extend_Output CLR
/ Clear
Dest SIM_Stamp.Extend_ScanCount
SIM_Stamp.Retract_Output 0

SIM_Stamp.Retract_Output LES
5 Less Than (A<B)
Source A SIM_Stamp.Retract_ScanCount
0
Source B 10

ADD
Add
Source A SIM_Stamp.Retract_ScanCount
0
Source B 1

Dest SIM_Stamp.Retract_ScanCount
0

SIM_Stamp.Retract_Output CLR
/ Clear
Dest SIM_Stamp.Retract_ScanCount
SIM_Stamp.Extend_Output 0

Logix Designer
R99_Simulate - Ladder Diagram Page 17
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:32 PM
Total number of rungs in routine: 31 G:\PROJECT\plc project 2\Project2Template.ACD

GRT SIM_Stamp.Retract_Output
6 Greater Than (A>B) /
Source A SIM_Stamp.Extend_ScanCount
0
Source B 3

SIM_Stamp.Extend_Timer.EN SIM_Stamp.Extend_Timer.DN
/

MOV TON
Move Timer On Delay EN
Source SIM_Stamp.Max Timer SIM_Stamp.Extend_Timer
500 Preset 500 DN
Dest SIM_Stamp.Extend_Timer.PRE Accum 0
500

SIM_Stamp.Retract_Sensor
U
SIM_Stamp.Extend_Sensor MOV
/ Move
Source SIM_Stamp.Extend_Timer.ACC
0
Dest SIM_Stamp.Animation
-18

SIM_Stamp.Extend_Timer.DN SIM_Stamp.Extend_Sensor
L

GRT SIM_Stamp.Extend_Output
7 Greater Than (A>B) /
Source A SIM_Stamp.Retract_ScanCount
0
Source B 3

SIM_Stamp.Retract_Timer.EN SIM_Stamp.Retract_Timer.DN
/

MOV TON
Move Timer On Delay EN
Source SIM_Stamp.Max Timer SIM_Stamp.Retract_Timer
500 Preset 500 DN
Dest SIM_Stamp.Retract_Timer.PRE Accum 0
500

SIM_Stamp.Extend_Sensor
U
SIM_Stamp.Retract_Sensor SUB
/ Subtract
Source A SIM_Stamp.Max
500
Source B SIM_Stamp.Retract_Timer.ACC
0
Dest SIM_Stamp.Animation
-18

SIM_Stamp.Retract_Timer.DN SIM_Stamp.Retract_Sensor
L

Logix Designer
R99_Simulate - Ladder Diagram Page 18
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:32 PM
Total number of rungs in routine: 31 G:\PROJECT\plc project 2\Project2Template.ACD

Stamp Lowered
I50.1
SIM_Stamp.Extend_Sensor <Ethernet5_WAGOIO:I.Data[0].1>
8
Stamp Raised
I50.0
SIM_Stamp.Retract_Sensor <Ethernet5_WAGOIO:I.Data[0].0>

SIM_RandomTimer.DN TON
9 / Timer On Delay EN
Timer SIM_RandomTimer
Preset 3561 DN
Accum 1282

DIV
10 Divide
Source A SIM_Stamp.Animation
-18
Source B SIM_Stamp.Max
500
Dest SIM_StampPercentExtend
-0.036

GRT CPT
Greater Than (A>B) Compute
Source A SIM_StampPercentExtend Dest CH0
-0.036 <Local:4:I.Ch0Data>
Source B 0.75 0.02
Expression 7+1*SIM_RandomTimer.ACC/3561

LEQ MOV
Less Than or Eql (A<=B) Move
Source A SIM_StampPercentExtend Source 0.02
-0.036
Source B 0.75 Dest CH0
<Local:4:I.Ch0Data>
0.02

--------------------------------------------
Stamp Secure Cylinder Sensor Simulation
--------------------------------------------
MCR ON Stamp Secure Extend
I2.5 O50.3
<Local:2:I.Data.5> <Ethernet5_WAGOIO:O.Data[0].3> SIM_Secure.Extend_Output
11
Stamp Secure Extend
O50.3
<Ethernet5_WAGOIO:O.Data[0].3> SIM_Secure.Retract_Output
/

Logix Designer
R99_Simulate - Ladder Diagram Page 19
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:32 PM
Total number of rungs in routine: 31 G:\PROJECT\plc project 2\Project2Template.ACD

SIM_Secure.Extend_Output LES
12 Less Than (A<B)
Source A SIM_Secure.Extend_ScanCount
0
Source B 10

ADD
Add
Source A SIM_Secure.Extend_ScanCount
0
Source B 1

Dest SIM_Secure.Extend_ScanCount
0

SIM_Secure.Extend_Output CLR
/ Clear
Dest SIM_Secure.Extend_ScanCount
SIM_Secure.Retract_Output 0

SIM_Secure.Retract_Output LES
13 Less Than (A<B)
Source A SIM_Secure.Retract_ScanCount
10
Source B 10

ADD
Add
Source A SIM_Secure.Retract_ScanCount
10
Source B 1

Dest SIM_Secure.Retract_ScanCount
10

SIM_Secure.Retract_Output CLR
/ Clear
Dest SIM_Secure.Retract_ScanCount
SIM_Secure.Extend_Output 10

Logix Designer
R99_Simulate - Ladder Diagram Page 20
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:32 PM
Total number of rungs in routine: 31 G:\PROJECT\plc project 2\Project2Template.ACD

GRT SIM_Secure.Retract_Output
14 Greater Than (A>B) /
Source A SIM_Secure.Extend_ScanCount
0
Source B 3

SIM_Secure.Extend_Timer.EN SIM_Secure.Extend_Timer.DN
/

MOV TON
Move Timer On Delay EN
Source SIM_Secure.Max Timer SIM_Secure.Extend_Timer
500 Preset 500 DN
Dest SIM_Secure.Extend_Timer.PRE Accum 0
500

SIM_Secure.Retract_Sensor
U
SIM_Secure.Extend_Sensor MOV
/ Move
Source SIM_Secure.Extend_Timer.ACC
0
Dest SIM_Secure.Animation
-18

SIM_Secure.Extend_Timer.DN SIM_Secure.Extend_Sensor
L

GRT SIM_Secure.Extend_Output
15 Greater Than (A>B) /
Source A SIM_Secure.Retract_ScanCount
10
Source B 3

SIM_Secure.Retract_Timer.EN SIM_Secure.Retract_Timer.DN
/

MOV TON
Move Timer On Delay EN
Source SIM_Secure.Max Timer SIM_Secure.Retract_Timer
500 Preset 500 DN
Dest SIM_Secure.Retract_Timer.PRE Accum 518
500

SIM_Secure.Extend_Sensor
U
SIM_Secure.Retract_Sensor SUB
/ Subtract
Source A SIM_Secure.Max
500
Source B SIM_Secure.Retract_Timer.ACC
518
Dest SIM_Secure.Animation
-18

SIM_Secure.Retract_Timer.DN SIM_Secure.Retract_Sensor
L

Logix Designer
R99_Simulate - Ladder Diagram Page 21
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:32 PM
Total number of rungs in routine: 31 G:\PROJECT\plc project 2\Project2Template.ACD

Secure Extended
I50.3
SIM_Secure.Extend_Sensor <Ethernet5_WAGOIO:I.Data[0].3>
16
I50.4
SIM_Secure.Retract_Sensor <Ethernet5_WAGOIO:I.Data[0].4>

--------------------------------------------
Transfer Cylinder Sensor Simulation
--------------------------------------------
MCR ON Extend Transfer
I2.5 O50.5
<Local:2:I.Data.5> <Ethernet5_WAGOIO:O.Data[0].5> SIM_Transfer.Extend_Output
17
Retract Transfer
O50.6
<Ethernet5_WAGOIO:O.Data[0].6> SIM_Transfer.Retract_Output

SIM_Transfer.Extend_Output LES
18 Less Than (A<B)
Source A SIM_Transfer.Extend_ScanCount
0
Source B 10

ADD
Add
Source A SIM_Transfer.Extend_ScanCount
0
Source B 1

Dest SIM_Transfer.Extend_ScanCount
0

SIM_Transfer.Extend_Output CLR
/ Clear
Dest SIM_Transfer.Extend_ScanCount
SIM_Transfer.Retract_Output 0

Logix Designer
R99_Simulate - Ladder Diagram Page 22
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:32 PM
Total number of rungs in routine: 31 G:\PROJECT\plc project 2\Project2Template.ACD

SIM_Transfer.Retract_Output LES
19 Less Than (A<B)
Source A SIM_Transfer.Retract_ScanCount
0
Source B 10

ADD
Add
Source A SIM_Transfer.Retract_ScanCount
0
Source B 1

Dest SIM_Transfer.Retract_ScanCount
0

SIM_Transfer.Retract_Output CLR
/ Clear
Dest SIM_Transfer.Retract_ScanCount
SIM_Transfer.Extend_Output 0

GRT SIM_Transfer.Retract_Output
20 Greater Than (A>B) /
Source A SIM_Transfer.Extend_ScanCount
0
Source B 3

SIM_Transfer.Extend_Timer.EN SIM_Transfer.Extend_Timer.DN
/

MOV TON
Move Timer On Delay EN
Source SIM_Transfer.Max Timer SIM_Transfer.Extend_Timer
1000 Preset 1000 DN
Dest SIM_Transfer.Extend_Timer.PRE Accum 0
1000

SIM_Transfer.Retract_Sensor
U
SIM_Transfer.Extend_Sensor MOV
/ Move
Source SIM_Transfer.Extend_Timer.ACC
0
Dest SIM_Transfer.Animation
-20

SIM_Transfer.Extend_Timer.DN SIM_Transfer.Extend_Sensor
L

Logix Designer
R99_Simulate - Ladder Diagram Page 23
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Total number of rungs in routine: 31 G:\PROJECT\plc project 2\Project2Template.ACD

GRT SIM_Transfer.Extend_Output
21 Greater Than (A>B) /
Source A SIM_Transfer.Retract_ScanCount
0
Source B 3

SIM_Transfer.Retract_Timer.EN SIM_Transfer.Retract_Timer.DN
/

MOV TON
Move Timer On Delay EN
Source SIM_Transfer.Max Timer SIM_Transfer.Retract_Timer
1000 Preset 1000 DN
Dest SIM_Transfer.Retract_Timer.PRE Accum 0
1000

SIM_Transfer.Extend_Sensor
U
SIM_Transfer.Retract_Sensor SUB
/ Subtract
Source A SIM_Transfer.Max
1000
Source B SIM_Transfer.Retract_Timer.ACC
0
Dest SIM_Transfer.Animation
-20

SIM_Transfer.Retract_Timer.DN SIM_Transfer.Retract_Sensor
L

SIM_Transfer.Extend_Sensor
22
SIM_Transfer.Retract_Sensor
Tranfer Extended
I50.5
<Ethernet5_WAGOIO:I.Data[0].5>
Transfer Retracted
I50.6
<Ethernet5_WAGOIO:I.Data[0].6>

Part At Stamp Secure Extended Stamp Lowered

I50.2 I50.3 I50.1
<Ethernet5_WAGOIO:I.Data[0].2> <Ethernet5_WAGOIO:I.Data[0].3> <Ethernet5_WAGOIO:I.Data[0].1> SIM_Stamped
23

SIM_Stamped

Logix Designer
R99_Simulate - Ladder Diagram Page 24
ABPROJECT2:MainTask:MainProgram 3/8/2016 5:20:32 PM
Total number of rungs in routine: 31 G:\PROJECT\plc project 2\Project2Template.ACD

Sensor Simulation

Part At Stamp
I50.2
SIM_SensorSimulate SIM_Travel.Active <Ethernet5_WAGOIO:I.Data[0].2>
24 / /

MOV TON
Move Timer On Delay EN
Source 500 Timer SIM_PartAtStampRefilDelay
Preset 500 DN
Dest SIM_PartAtStampRefilDelay.PRE Accum 0
500

Part At Stamp
I50.2
SIM_PartAtStampRefilDelay.DN <Ethernet5_WAGOIO:I.Data[0].2>
L

MOV MOV SUB

25 Move Move Subtract
Source 3000 Source 500 Source A SIM_Travel.Time.PRE
3000
Dest SIM_Travel.Time.PRE Dest SIM_Travel.Leave Source B SIM_Travel.Leave
3000 500 500
Dest SIM_Travel.Max
2500

Logix Designer
R99_Simulate - Ladder Diagram Page 25
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Total number of rungs in routine: 31 G:\PROJECT\plc project 2\Project2Template.ACD

SIM_SensorSimulate
26

Conv Run Part At Stamp Part Stop Extend

O51.0 I50.2 O50.2
<Ethernet5_WAGOIO:O.Data[1].0> <Ethernet5_WAGOIO:I.Data[0].2> <Ethernet5_WAGOIO:O.Data[0].2>
/
GRT SIM_Travel.Time.DN
Greater Than (A>B) /
Source A SIM_Travel.Time.ACC
0
Source B SIM_Travel.Leave
500

RTO
Retentive Timer On EN
Timer SIM_Travel.Time
Preset 3000 DN
Accum 0

Part At Stamp
I50.2
SIM_Travel.Time.TT GRT <Ethernet5_WAGOIO:I.Data[0].2>
Greater Than (A>B) U
Source A SIM_Travel.Time.ACC
0
Source B SIM_Travel.Leave
500

SIM_Travel.Active
L
Part At Transfer
I50.7
SIM_Travel.Time.DN <Ethernet5_WAGOIO:I.Data[0].7> SIM_Travel.Time SIM_Travel.Active
L RES U
SUB
Subtract
Source A SIM_Travel.Time.ACC
0
Source B SIM_Travel.Leave
500
Dest SIM_Travel.Animation
-500

MOV MOV SUB

27 Move Move Subtract
Source 2000 Source 250 Source A SIM_Ramp.Time.PRE
2000
Dest SIM_Ramp.Time.PRE Dest SIM_Ramp.Leave Source B SIM_Ramp.Leave
2000 250 250
Dest SIM_Ramp.Max
1750

Logix Designer
R99_Simulate - Ladder Diagram Page 26
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Total number of rungs in routine: 31 G:\PROJECT\plc project 2\Project2Template.ACD

Part At Transfer Extend Transfer

I50.7 O50.5
SIM_SensorSimulate <Ethernet5_WAGOIO:I.Data[0].7> <Ethernet5_WAGOIO:O.Data[0].5>
28
GRT SIM_Ramp.Time.DN
Greater Than (A>B) /
Source A SIM_Ramp.Time.ACC
0
Source B SIM_Ramp.Leave
250

RTO
Retentive Timer On EN
Timer SIM_Ramp.Time
Preset 2000 DN
Accum 0

Part At Transfer
I50.7
SIM_Ramp.Time.TT GRT <Ethernet5_WAGOIO:I.Data[0].7>
Greater Than (A>B) U
Source A SIM_Ramp.Time.ACC
0
Source B SIM_Ramp.Leave
250

SIM_Ramp.Active
L
Ramp Is Full
I51.0
SIM_Ramp.Time.DN <Ethernet5_WAGOIO:I.Data[1].0> SIM_Ramp.Time SIM_Ramp.Active
L RES U
SUB
Subtract
Source A SIM_Ramp.Time.ACC
0
Source B SIM_Ramp.Leave
250
Dest SIM_Ramp.Animation
-250

Ramp Is Full
I51.0
SIM_SensorSimulate <Ethernet5_WAGOIO:I.Data[1].0>
29

MOV TON
Move Timer On Delay EN
Source 2000 Timer SIM_PartOnRampDelay
Preset 2000 DN
Dest SIM_PartOnRampDelay.PRE Accum 0
2000

Ramp Is Full
I51.0
SIM_PartOnRampDelay.DN <Ethernet5_WAGOIO:I.Data[1].0>
U

SIM_SensorSimulate SIM_Travel.Active SIM_Ramp.Active

30 / U U

Logix Designer
R99_Simulate - Ladder Diagram Page 27
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Total number of rungs in routine: 31 G:\PROJECT\plc project 2\Project2Template.ACD

(End)

Logix Designer
MainRoutine - Ladder Diagram Page 28
ABPROJECT2:SafetyTask:SafetyProgram 3/8/2016 5:20:33 PM
Total number of rungs in routine: 0 G:\PROJECT\plc project 2\Project2Template.ACD

(End)

Logix Designer
ABPROJECT2 - Table of Contents Page i
3/8/2016 5:20:33 PM
G:\PROJECT\plc project 2\Project2Template.ACD

ABPROJECT2
MainTask
MainProgram
R01_MainRoutine
Ladder Diagram ......................................................................................................................................................................................................1
R02_StampStation
Ladder Diagram ......................................................................................................................................................................................................3
R03_TransferStation
Ladder Diagram ......................................................................................................................................................................................................7
R04_FalseSensorTrigger
Ladder Diagram ......................................................................................................................................................................................................8
R05_PartTimingCountng
Ladder Diagram ......................................................................................................................................................................................................9
R06_PartStopSecureFaults
Ladder Diagram ....................................................................................................................................................................................................12
R07_StampPressure
Ladder Diagram ....................................................................................................................................................................................................13
R08_Ramp
Ladder Diagram ....................................................................................................................................................................................................14
R99_Simulate
Ladder Diagram ....................................................................................................................................................................................................15
SafetyTask
SafetyProgram
MainRoutine
Ladder Diagram ....................................................................................................................................................................................................28

Logix Designer