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Automating Manufacturing Systems
with PLCs
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(Version 5.0, May 4, 2007)
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Hugh Jack
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Copyright (c) 1993-2007 Hugh Jack (jackh@gvsu.edu).
Permission is granted to copy, distribute and/or modify this document under the
terms of the GNU Free Documentation License, Version 1.2 or any later version
published by the Free Software Foundation; with no Invariant Sections, no
Front-Cover Texts, and no Back-Cover Texts. A copy of the license is included
in the section entitled "GNU Free Documentation License".
This document is provided as-is with no warranty, implied or otherwise. There
have been attempts to eliminate errors from this document, but there is no doubt
that errors remain. As a result, the author does not assume any responsibility for
errors and omissions, or damages resulting from the use of the information pro-
vided.
Additional materials and updates for this work will be available at http://clay-
more.engineer.gvsu.edu/~jackh/books.html
page i
1.1
TODO LIST
1.3
2.
PROGRAMMABLE LOGIC CONTROLLERS . . . . . . . . . . . . . 2.1
2.1
INTRODUCTION
2.1
2.1.1
Ladder Logic
2.1
2.1.2
Programming
2.6
2.1.3
PLC Connections
2.10
2.1.4
Ladder Logic Inputs
2.11
2.1.5
Ladder Logic Outputs
2.12
2.2
A CASE STUDY
2.13
2.3
SUMMARY
2.14
2.4
PRACTICE PROBLEMS
2.15
2.5
PRACTICE PROBLEM SOLUTIONS
2.15
2.6
ASSIGNMENT PROBLEMS
2.16
3.
PLC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.1
INTRODUCTION
3.1
3.2
INPUTS AND OUTPUTS
3.2
3.2.1
Inputs
3.3
3.2.2
Output Modules
3.7
3.3
RELAYS
3.13
3.4
A CASE STUDY
3.14
3.5
ELECTRICAL WIRING DIAGRAMS
3.15
3.5.1
JIC Wiring Symbols
3.18
3.6
SUMMARY
3.22
3.7
PRACTICE PROBLEMS
3.22
3.8
PRACTICE PROBLEM SOLUTIONS
3.25
3.9
ASSIGNMENT PROBLEMS
3.28
4.
LOGICAL SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1
INTRODUCTION
4.1
4.2
SENSOR WIRING
4.1
4.2.1
Switches
4.2
4.2.2
Transistor Transistor Logic (TTL)
4.3
4.2.3
Sinking/Sourcing
4.3
4.2.4
Solid State Relays
4.10
4.3
PRESENCE DETECTION
4.11
4.3.1
Contact Switches
4.11
4.3.2
Reed Switches
4.11
4.3.3
Optical (Photoelectric) Sensors
4.12
4.3.4
Capacitive Sensors
4.19
4.3.5
Inductive Sensors
4.23
4.3.6
Ultrasonic
4.25
4.3.7
Hall Effect
4.25
page ii
4.3.8
Fluid Flow
4.26
4.4
SUMMARY
4.26
4.5
PRACTICE PROBLEMS
4.27
4.6
PRACTICE PROBLEM SOLUTIONS
4.30
4.7
ASSIGNMENT PROBLEMS
4.36
5.
LOGICAL ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.1
INTRODUCTION
5.1
5.2
SOLENOIDS
5.1
5.3
VALVES
5.2
5.4
CYLINDERS
5.4
5.5
HYDRAULICS
5.6
5.6
PNEUMATICS
5.8
5.7
MOTORS
5.9
5.8
OTHERS
5.10
5.9
SUMMARY
5.10
5.10
PRACTICE PROBLEMS
5.10
5.11
PRACTICE PROBLEM SOLUTIONS
5.11
5.12
ASSIGNMENT PROBLEMS
5.12
6.
BOOLEAN LOGIC DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
6.1
INTRODUCTION
6.1
6.2
BOOLEAN ALGEBRA
6.1
6.3
LOGIC DESIGN
6.6
6.3.1
Boolean Algebra Techniques
6.13
6.4
COMMON LOGIC FORMS
6.14
6.4.1
Complex Gate Forms
6.14
6.4.2
Multiplexers
6.15
6.5
SIMPLE DESIGN CASES
6.17
6.5.1
Basic Logic Functions
6.17
6.5.2
Car Safety System
6.18
6.5.3
Motor Forward/Reverse
6.18
6.5.4
A Burglar Alarm
6.19
6.6
SUMMARY
6.23
6.7
PRACTICE PROBLEMS
6.24
6.8
PRACTICE PROBLEM SOLUTIONS
6.27
6.9
ASSIGNMENT PROBLEMS
6.37
7.
KARNAUGH MAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1
INTRODUCTION
7.1
7.2
SUMMARY
7.4
7.3
PRACTICE PROBLEMS
7.5
7.4
PRACTICE PROBLEM SOLUTIONS
7.11
page iii
7.5
ASSIGNMENT PROBLEMS
7.17
8.
PLC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.1
INTRODUCTION
8.1
8.2
OPERATION SEQUENCE
8.3
8.2.1
The Input and Output Scans
8.4
8.2.2
The Logic Scan
8.4
8.3
PLC STATUS
8.6
8.4
MEMORY TYPES
8.6
8.5
SOFTWARE BASED PLCS
8.7
8.6
SUMMARY
8.7
8.7
PRACTICE PROBLEMS
8.8
8.8
PRACTICE PROBLEM SOLUTIONS
8.8
8.9
ASSIGNMENT PROBLEMS
8.9
9.
LATCHES, TIMERS, COUNTERS AND MORE . . . . . . . . . . . . 9.1
9.1
INTRODUCTION
9.1
9.2
LATCHES
9.2
9.3
TIMERS
9.6
9.4
COUNTERS
9.14
9.5
MASTER CONTROL RELAYS (MCRs)
9.17
9.6
INTERNAL BITS
9.19
9.7
DESIGN CASES
9.20
9.7.1
Basic Counters And Timers
9.20
9.7.2
More Timers And Counters
9.21
9.7.3
Deadman Switch
9.22
9.7.4
Conveyor
9.23
9.7.5
Accept/Reject Sorting
9.24
9.7.6
Shear Press
9.26
9.8
SUMMARY
9.27
9.9
PRACTICE PROBLEMS
9.28
9.10
PRACTICE PROBLEM SOLUTIONS
9.32
9.11
ASSIGNMENT PROBLEMS
9.43
10.
STRUCTURED LOGIC DESIGN . . . . . . . . . . . . . . . . . . . . . . . 10.1
10.1
INTRODUCTION
10.1
10.2
PROCESS SEQUENCE BITS
10.2
10.3
TIMING DIAGRAMS
10.6
10.4
DESIGN CASES
10.9
10.5
SUMMARY
10.9
10.6
PRACTICE PROBLEMS
10.9
10.7
PRACTICE PROBLEM SOLUTIONS
10.10
10.8
ASSIGNMENT PROBLEMS
10.14
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