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Pneumatic circuits
8 4 6 5 9 1 2 3 10
7
Supply Side Usage Side
5 6 1 3 2
spring-return
tepping away from this mat, the person has to manually switch the robot back ON
a 3/2 valve
valve actuation
a 5/2 valve
return spring
pneumatic
foot pedal
push button
solenoid (electrical)
roller (mechanical)
A-
A+ VA
Start
- 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-
A +
a 1 B + V A + b 1 C + V B + c 1 b 2 S t a r t V C + 1 2 2 C a s c a d e c ic r u i t 1 a 2
- For more complex logic, difficult to debug - Less versatile than electronic control (e.g. no counters, poor timer control)
ut inp
u inp
in p t5
6 ut
ut
u np 1 i
C A/ 0V 22
u inp
t0
PLC: example 1
to PLC Output: 1
warning bulb
robot
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
I:0/1
O:0/1
PLC: example 1
I:0/1
O:0/1
IF
THEN
PLC: example 2
to PLC Output: 1
warning bulb
robot
Sensor output, connected to PLC Input: 1 Sensor output, connected to PLC Input: 2
inner pressure sensitive mat to PLC Output: 2 outer pressure sensitive mat
Outer mat ON warning light ON Inner mat ON warning light ON AND Robot OFF
PLC: example 2
Two actuators: Warning light, Robot master switch LOGIC for Warning light External Input 1: outer mat
I:0/1 O:0/1
I:0/2
PLC: example 2
I:0/1
O:0/1
I:0/2
O:0/2
WRONG !
PROBLEM ?
PLC: example 2
LOGIC for Robot Robot must STAY OFF until manual reset to ON Solution: LATCH External Input 2: inner mat latch
I:0/2 O:0/3
Incomplete
O:0/3
O:0/3
O:0/2
PLC: example 2
LOGIC for Robot Robot must STAY OFF until manual reset to ON
I:0/1 O:0/1 Legend: I:0/2 I:0/1 connected to Outer Mat Switch I:0/2 I:0/3 B1 I:0/2 connected to Inner Mat Switch I:0/3 connected to Push Button for robot reset O:0/1 connected to warning light B1 I:0/2 O:0/2 O:0/2 connected to robot
B1
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.
(i) ON signal from number-pad outside door (ii) ON signal from door-open switch inside door Legend:
I:0/1 Number Pad Signal to open door I:0/2 Push Button signal to open door O:0/1 Solenoid to unlock door
I:0/2
O:0/1
O:0/1
Timer:
T4: 1
EN DN
While O:0/1 remains ON, Timer COUNTS DOWN from PRESET COUNT DOWN = 0 ( T4:1) set to ON
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
I:0/1 T4: 1 DN I:0/2 I:0/1 Number Pad Signal to open door O:0/1 I:0/2 Push Button signal to open door O:0/1 Solenoid to unlock door O:0/1
Timer: T4: 1 EN DN
O:0/1 Legend:
Leg
I:0/ O:0/1
During ON, if button is pressed, Timer resets to PRESET During ON, light indicator is ON
I:0/
O:0 O:0/1
Timer: T4: 1 EN DN
O:0
LEGEND: I:0/1 door-open I:O/2 card-reader O:0/1 solenoid O:0/2 light indicator
O:0/1
O:0/2
I:0/2
T4: 1 RESET
I:0/1
I:0/0 Conveyor ON I:0/1 Photo switch I:0/2 Operator controlled Push Button to restart conveyor
I:0/2
C5: 1 RESET
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
I1 : 0 /
I2 : 0 /
B 1
B 1 T 4 : 0 E N B a s e : P rt e s e A c c u m : B 1 T 4 : 1 E N B a s e : P rt e s e : A c c u m : 0 . 0 1 6 0 0 0 0 T 4 : 2 E N B a s e : P rt e s e : A c c u m : B 1 T 4 : 0 T 4 : 1 0 . 0 1 7 5 0 0 0 T 4 : 2 D N T 4 : 2 D N T 4 : 2 D N C 5 : 0 E N P rt e s e : A c c u m : C 5 : 0 D N I : 3 0 / 5 0 0 O : 0 / 3 O : 0 / 0 : 0 . 0 1 3 0 0 0 0
I01:Sse O :/ yt m n I02:E egnySo :/ mr e c t p I03: L i S ic :/ i t wh m t O / : Sa W rO : 0 op a 0 te n O / :R s O : 1 i e n 0 n O / : Sr b e O : 2 c u br n 0 O / : Atv t Sr b e Ca g : 3 ci ae cu b r hn e 0 Ntc h w 1a dt etmro t usae oi e o B n h i e up t r ue t c nr lt el gc s do oto h oi a c r i gt th r q ir dt i g c odn o e e u e im . n
B 1
B 1
D N D N T 4 : 0 T 4 : 1 D N D N T 4 : 0 T 4 : 1 D N D N
O : 0 / 1
B 1
O : 0 / 2
O : 0 / 2 C T U
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
T 4 : 0 R E S
I : 3 0 /
T 4 : 1 R E S
I : 3 0 /
T 4 : 2 R E S C: 50 R E S
O : 0 / 3
Programming a 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
00 01 02 03 04 05
00 Program Memory
30
30 31 32 33