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Industrial Automation Using PLCs - System Design Problems

The document provides 13 examples of PLC programming problems involving logic circuits, mathematical operations, process control applications, and counting/display functions. The problems cover concepts such as binary to BCD conversion, latching/unlatching outputs, timers, subroutines, liquid level control, temperature control, part counting on a conveyor, and using the MCR instruction to reset outputs. The goal is to write the PLC ladder logic and code to solve each problem.

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Bonface Mugwira
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302 views

Industrial Automation Using PLCs - System Design Problems

The document provides 13 examples of PLC programming problems involving logic circuits, mathematical operations, process control applications, and counting/display functions. The problems cover concepts such as binary to BCD conversion, latching/unlatching outputs, timers, subroutines, liquid level control, temperature control, part counting on a conveyor, and using the MCR instruction to reset outputs. The goal is to write the PLC ladder logic and code to solve each problem.

Uploaded by

Bonface Mugwira
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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INDUSTRIAL AUTOMATION USING PLCs

System Design Examples


The following are PLC programming design examples. A description of each problem is
provided. In each case, write down the solution as well as the PLC code. Ensure your Ladder
diagrams are well commented.

1. Write a PLC program to implement the combinational logic circuit shown in the figure
below.

2. Write a PLC program to implement a 3-bit Binary to BCD Converter.


3. Write a PLC program to perform Latching and unlatching of an output (You can use a
Pilot Light, Motor, Solenoid Coil etc. as the output.)
4. Modify the PLC program in question 3 above to accommodate a time delay. (Hint:
Include a TON timer in your design).
5. A typical classroom at the University of Nairobi has a maximum capacity of 120
students. There are two doors, one for Entry and the other for Exit.
When the number of students in the classroom is less than 120, Entry door has a Green
light on it which remains ON.
When number of students in the classroom is 120 or more than that, Red light goes ON
turning OFF the Green light which indicates that the classroom has reached its
maximum capacity and is full.
Design a PLC program to maintain the capacity of this classroom.
Hint: Use proximity switches to detect entry and exit of students. Also, make use of a
counter and a comparator.
6. You are required to implement a PLC program to control lights in a sequence using
retentive timers. Design a PLC ladder diagram to control five Pilot Lights in a sequence
with a 0.5s time delay between each pair of lights.

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7. Design a PLC program to implement the following mathematical functions, all in one
ladder diagram.
ADD, SUB, MUL, DIV, SQR and NEG
8. You are working in a hazardous area where some action must be taken immediately
despite of the status of a currently running process. Draw a ladder diagram that
implements the jump instruction in a case where a Latch output exists between JMP
and LBL rungs.
Note: As long as JMP is energized, all the output between JMP and LBL rungs are
skipped. Also note that if Latch Output is used between JMP-LBL rungs and is active
then it is not unlatched when JMP energizes.
9. A final year project requires a student to add temperature outputs of two temperature
transmitters and display the total temperature. The display is to be updated every 10
seconds when the system is active.
Using a Subroutine program, write a PLC program to implement this system.
Note: When we use subroutine instruction, Subroutine address must be same in JSR
instruction of main program and RET instruction of subroutine program.
10. One open tank is installed in a plant of which the liquid level is to be controlled. When
the level reaches Level Low, Outlet flow is blocked and inlet flow is allowed until high
level is achieved. And when Level High is detected, outlet flow is allowed and inlet
flow is blocked.

Write a PLC program to control the liquid level in this tank.


11. A system is designed to control the heating of a liquid in the tank using a heater. The
description is as follows:
 To detect high and low level of liquid in the tank, two level switches are used
which gives output in digital terms, that is when corresponding levels are
detected, it gives output high otherwise remain low.
 To control level of this system, Single Acting Piston valve can be used which
has two states, either fully open or fully close and to heat the liquid, heater is
used.

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 Low Level Switch is mounted at the bottom of the tank and Level High switch
is mounted at the side-upper most position.
 Heater is installed inside the tank and temperature sensor such as RTD or
Thermocouple may be used to detect the temperature of liquid in the tank.
Write a PLC program to achieve this control process.
12. You have been recently employed at an industry on Mombasa road. The industry has
parts that are moved on the conveyor. You are required to design a system using PLC
to count the number of parts collected at the end of the conveyor and display it on the
display as shown below.

Implement this design using the following guidelines:


 Mount Proximity Switch to detect the parts.
 Use output of proximity to counter as an input to increment data.
 Convert this number into appropriate numerical and show number of parts collected.
 Most widely Inductive and Capacitive Proximity switches are used to detect parts.
 Inductive Proximity are used to detect metal objects while to detect other objects,
Capacitive Proximity Switch is most widely used.
 Capacitive Proximity detection capability ranges from 1 to 25mm distance.
 Mount this sensor according to the size of parts present on the conveyor and width of
conveyor so that this sensor can detect parts easily.
 CUP is used to increment the number of parts collected.
13. Write a PLC program to reset all Non-retentive outputs of a process. Implement this
using MCR instruction in PLC ladder diagram.
Note:
 By using Master Control Relay MCR instruction, we can solve this problem.
 When this instruction is enabled, the line is energized, it turns on.
 When MCR is OFF, the number of the subsequent ladder diagram lines specified are
turned off.
 In many PLCs, all outputs are turned off while in some PLCs, only Non-retentive
outputs are turned off.
 In PLCs such Allen Bradley and Siemens, all non-retentive outputs are turned off.
 The MCR must be turned on to be inactive. If the function goes off for some reason, it
is active and turns the specified lines off.

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