Project
1.0 Objective
This experiment aims to design and implement a specified PLC project.
1.1 Projects Specifications
Lab groups are assigned projects according to a draw.
1.1.1 Project 1: 4-Way Intersection Traffic Light Controller
Use the PLC to control the traffic light system for the 4-way intersection in figure 1. Directions 1 & 2 must pass exclusively, each for 40 seconds. Directions 3 & 4 pass concurrently for 25 seconds. To make it simple, your traffic lights contain the red and green colors only.
Figure 1. 4-way intersection diagram.
1.1.2 Project 2: 3-Way Intersection Traffic Light Controller
Use the PLC to control the traffic light system for the 3-way intersection in figure 2. Directions 1, 2 & 3 must pass exclusively, each for 40 seconds. Direction 4 stops only when direction 2 is passing. To make it simple, your traffic lights contain the red and green colors only.
Figure 2. 3-way intersection diagram.
1.1.3 Project 3: PSUT/RSS Exits Traffic Light Controller
Design a traffic light system controller for the PSUT/RSS exits junction, see figure 3. Positions 1 & 2 shall remain on continuously except when: a) a car exiting RSS activates a sensor switch. In this case the system waits for 20 seconds then closes 1 & 2 and opens 3 for 5 seconds. b) a car exiting PSUT activates a sensor switch. In this case the system waits for 20 seconds then closes 1 & 2 and opens 4 for 5 seconds.
Figure 3. PSUT/RSS exits intersection diagram
1.1.4 Project 4: Plastic Pipe Production System
Figure 4. Pipe Production System A system for producing plastic pipes uses a pressure piston motor that presses heated plastic out of a nozzle. When the pipe reaches the required length it closes the pipe length limit switch. The produced pipe must then be cut by the saw motor and a label is stamped by a solenoid on the pipe. The saw and stamp need 15s to finish. After this another solenoid is activated to push the pipe to the side making way for a new pipe to be produced. During the pressing the temperature of the plastic must be at the temperature sensor activation value.
1.1.5 Project 5: Car Paint System
Figure 5. Car Paint System. The diagram shows a car paint oven. The painting operation consist of spray painting for 10minutes, followed by heating at 30 for 30minutes and ending in air circulation by the fan for 5minutes. Upon completion a green lamp turns on at the operator panel.
The system is started by the operator with an (On) button. The system should not start if the door is open. An emergency (Off) switch is also available. Design and implement a PLC program for the system. Use seconds instead of minutes in your implementation test.
1.1.6 Project 6: Hydroponics System
Figure 6. Hydroponics System. Design and implement a PLC program to control the automated hydroponics system shown above ( .) The system must implement the following: Throughout the day a nutrient liquid is cycled to the plants: A solenoid valve is opened to fill the container up to level limit switch 1. The nutrient is kept there for 2 hours. Next the plaints container is emptied by the pump to level limit switch 2, and kept empty for two more hours, and so on. Light must reach the plants for 8 hours per day. If sun light is not available during those 8 hours an artificial white light is switched on. Sun light is detected by a photoswitch which closes on direct sunlight.
For testing your project implementation convert each hour to 10 seconds.
1.1.7 Project 7 : Goods Elevator
A goods elevator moves between 3 floors. The elevator has 3 external request buttons/switches I08 to I10, and an internal floor choice button/switch for up or down, a door obstructed switch I14, and a user/load present sensor/switch I15. Two relays are used to activate the elevator motor, up (relay Q00) and down (relay Q01). If a user/load is in the elevator the system will only respond to the internal switches and move to the direction. When there is no load in the elevator it will move to the activated external switch floor. To move between adjacent floors the motion relay must be activated for 10s. Elevator door will stay open for 5s before reclosing if its load sensor is not activated or if the door is obstructed. The door motor is activated by two relays open (relay Q03) and close (relay Q04).
1.1.8 Project 8: Hot Drinks Dispenser
A dispensing machine is used to provide hot drinks according to selecting buttons/switches I08 for coffee, I09 coffee with cream, I10 for tea, I11 for tea with milk. The user can add sugar to any of his drinks by selecting button/switch I12. A cup is placed by the dispenser through relay Q00. Placing a cup takes 5 seconds. After that hot water is poured into the cup by relay Q01 for 8 seconds. Following the water relays Q02 to Q06 are activated according to the selection buttons, in order, for 1 second. If no cup is present no water or items should be dispensed and an alarm lamp Q07 should be activated. Cup presence is detected by switch I13. Water is kept hot by a heater activated by an external thermostat. Its temperature is measured by sensor/switch I14. If the water is hot enough lamp Q08 is switched on. If the water is not hot enough no dispensing should take place.
1.1.9 Project 9: Bottling Plant
A bottling plant consists of a moving conveyor belt activated by relay Q00. When a bottle reaches the filling station it is detected by sensor/switch I08. The belt is stopped and the bottle is filled by liquid valve relay Q01. Filling each bottle takes 20 seconds. The bottle is then moved by the conveyor belt to the cap fixing station. If a bottle is present, detected by limit switch I11, cap place solenoid is activated by relay Q02, the cap is then screwed in by motor/relay Q03 for 3 seconds.
A juice container is used to supply the bottles. Sensor/switch I09 detects if juice level reaches its low level. A pump Q04 should be activated to refill the container up to its maximum detected by level sensor I10.
1.1.10 Project 10: Vending Machine System
A machine for vending sandwiches accepts two kinds of coins (5 piasters and 10 piasters). A switch is activated every time a coin is inserted in the machine. Two coin paths exist for each denomination. The 5 piasters coin is placed on edge and its height is detected by 2 switches (short and tall). These detectors are used to determine if the coin is genuine. Similarly for the 10 piasters coin. The machine is used to sell 2 types of sandwiches. Sandwich A costs 20 piasters, sandwich B costs 25 piasters. Each type of sandwich is selected by a different switch and ejected by a different relay. The design should ensure that the correct amount of coins is placed in the system for each sandwich.
1.1.11 Project 11: Liquid Agitation System
By pressing a start switch a tank is filled with a liquid by a valve activated by a relay. When a switch sensor detects that the tank is full, a motor is activated by a relay to stir the liquid for 20 seconds. Afterwards the tank is emptied by another valve until an empty tank switch is closed. The process is then repeated automatically until a stop button is pressed. An indicator lamp is switched on when this process is repeated five times.
1.1.12 Project 12: Elevator System
An elevator for transport between 2 floors uses 2 DC motors one for up, the other for down. The position of the elevator is detected by two limit switches at each floor. A motion switch is inside the elevator for motion. And each floor has one call switch.
1.1.13 Project 13: Water Pumping System
A pump is activated by a relay to move water from a ground tank to a roof tank. The ground tank has a low water level sensor switch. The roof tank has one low level and one full sensor. When the roof tank is low the pumping must be activated until the tank is full. The pump should not work if the ground tank is empty. For record keeping, the number of pumping times should be kept. Include the operator switches in your ladder.
1.1.14 Project 14: Car Park System
A car park has capacity for five cars. The entrance gate motor is switched on by a relay when a car stops at an entrance sensor switch. The same applies for the exit gate. If the car park is full, a sign (FULL) should be switched on by a relay, and the entrance door should not open.
1.1.15 Project 15: Garden Watering System
A garden watering system consists of a temperature sensor switch and a humidity switch. If the temperature is high and the humidity low, the watering system should work as follows: The water pump is started; grass valve relay is activated for 5sec, then the flowers valve for 10sec, then the trees valve for 15sec and the sequence is repeated.
1.1.16 Project 16: Bottling System
Empty bottles are moved on a conveyor belt by a motor relay. When a bottle reaches a limit switch, the belt is stopped and a fill valve relay is activated for 3seconds. The belt is then moved. When 6 bottles are filled a relay is activated to pack the bottles.
1.1.17 Project 17: Pedestrian Crossing System
A traffic light is used to facilitate pedestrian crossing on a busy road (e.g. Gardens street). A pushbutton switch is available for the pedestrians wishing to cross. When pressed the traffic light for the cars turns to yellow for 5 seconds and then to red. It stays red for 15 seconds. At the same time the green pedestrian light is switched on. The pedestrian green light starts to flash for the last 5 seconds of the 15. Then the green light for the cars and the red for pedestrians are turned on. Any new request for pedestrians will not be accepted for the next 2 minutes. All lights are activated by relays.
1.1.18 Project 18: Conveyor Drilling System
A conveyor belt is driven by a motor relay to move items to a drilling station. When an item reaches the drilling area a limit switch is activated. The belt is stopped, a drill is moved down by a relay until position limit switch 3 is activated. The drill starts to rotate while moving down till limit switch 4 is reached, at which point the required hole is finished. The drill rotation is stopped and it is pulled up by another relay until it reaches limit switch 2. Then the belt is moved again. A counter is used to determine the number of items drilled.
1.1.19 Project 19: Liquid Processing System
A liquid container must be kept full by an in-valve relay. The liquid level is measured by two sensor switches. A full sensor switch and low sensor switch. Steam is passed through the liquid to keep its temperature at 70C. If the temperature drops below 70C the sensor switch will open. The steam valve relay is opened to allow steam into the container until the temperature is restored.
1.1.20 Project 20: Heat Treatment System
The operator places a metal part on a fixture, and then pushes the start switch. An inductive heating coil heats the part rapidly to 1500F. When the temperature reaches 1500, a sensor output becomes true. The coil turns off, and a valve is opened which sprays water for 5seconds on the part to quench the part. The operator then removes the part and the sequence begins again. Note if a part is not present the sequence will not start. The system should turn on a light every time 8 parts are completed.
1.1.21 Project 21: Canal Locks
Figure 7. Canal Locks. To raise the ships to higher levels in canals a lock mechanism is used. When a ship arrives from either direction (sensed by switches) a pump is activated to empty/fill the lock to the suitable level. Two solenoid valves are used to control the fill or empty operation. After reaching the suitable water level (sensed by switches), the appropriate gate is opened for 20seconds to allow the ship into the lock. The gate is then closed and the pump is started again to achieve the required water level. The second gate is then opened for 20seconds to allow the ship to exit the lock. For safety considerations the gates should not open when pumping is ongoing.
4.2
Pre-lab
You are required to design a ladder diagram to control the system specified in your project.
4.3
In-lab
Download and run your design on the PLC. Test the working of your system. Verify your system with the lab instructor. Bring a hardcopy of your ladder diagram for the discussion part.
4.4
ladder.
Hand in
Hand in a full report about your design. Include an explanation for each rung of the
4.5
Grading
The grade for this lab will count towards 15% of your lab grade. It will depend on the correct implementation of the specification, successful run of the ladder on the PLC, your report and most important of all: an individual discussion with the instructor about your work.