This PLC ladder logic programming tutorial explains how to develop a pneumatic circuit and PLC ladder logic program using FESTO fluid sim. The operation of the process is as follows:
While placing the wooden block, the contact switch is activated and produces the stating signal for the automated process. Then clamping cylinder extend and clamp the wooden block and it increases the clamping force until the cylinder pressure reaches 6 bar. Then drilling cylinder begins to extend and at the beginning of extension drilling motor also starts. Drilling cylinder extent until it reaches the cylinder front end reed switch. Then it backwards and when it reaches the back position drilling motor switches off. Then clamping cylinder backwards, and wooden block can be removed
Then machine is ready to next cycle
Two double acting cylinders are used in here as clamping cylinder and drilling cylinder. pressure switch and pressure indicator is used to detect the clamping pressure, and two 5/2-way solenoid activated directional control vales used in here. S1 sensor is used to detect the clamping cylinder back position and s3 and s4 reed switches are being used to detect the end position of the drilling cylinder.
One critical aspect to note is that a pressure sensor switch is utilized to determine the clamped position of the clamping cylinder, rather than employing a reed switch. If a reed switch were used, the signal it generates could vary depending on the size of the wooden workpiece. To circumvent such issues, a pressure sensor switch is employed. By using the signal from the pressure sensor switch, it is possible to confirm that the wooden block is securely clamped and ready for drilling.
The PLC ladder logic program for this prosses having the step sequence structure.
Entire process is divided in to four steps
➡️Step 1 is extraction of cylinder to clamp the wooden block
➡️Step 2 is extraction of drilling cylinder
➡️Step 3 is retraction of drilling cylinder
➡️step 4 is retraction of clamping cylinder
First network is the start latch and it switch on the START memory until it reset from stop button
Second network is to detect the existence of wooden block for drilling, that signal is taken by the contact switch for this any proximity sensor also can be use. when the signal reaches it switch on the Block is Ready memory.
Third network switch on the step 1 completed memory. That memory is trigger when block is present and clamping has finished. Clamping has finished is detect by the pressure sensor switch.
Fourth network is to extract the clamping cylinder extraction condition is start memory and block is ready memory and step 1 is not completed.
Fifth network is to remember the step 2 has completed. To set the “step 2 completed memory” step 1 completed memory and sensor 4 signal should reach.
Sixth network is to extract the drilling cylinder, extraction is done when reaching the start memory and step1 completed memory and step 2 completed memory is not there.
Seventh network is to start the drill motor. Drilling motor is starts when the start memory is set and s3 sensor signal is not there. That mean drilling motor is stars at the beginning of drilling cylinder extraction.
Eighth network is to remember drilling process has finished. It triggers with step 2 completed memory and S3 sensor signal.
Nineth network is to retract the drilling cylinder, it triggers when start memory is set and step2 completed memory is set and step 3 completed memory is not set situation.
Tenth network is to remember the step4 is completed that trigger when with step 3 completed memory and s1 sensor signal.
Eleventh network is to retract the clamping cylinder that triggers when start memory set and step 3 completed memory is set and step 4 completed memory is not set situation.
After completion the one process five memory bit goes to set state
Block is ready memory
➡️Step 1 completed memory
➡️Step 2 completed memory
➡️Step 3 completed memory
➡️Step 4 completed memory
All of these memories reset when removing the wooden block because when removing the wooden block block is ready memory goose to zero and subsequent memories of Step 1 completed memory, Step 2 completed memory, Step 3 completed memory, Step 4 completed memory are goes to zero. Then machine is ready take next wooden block.
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