SEQUENCE AND

LOGIC CONTROL
Module 5
 What is Sequence and Logic Control?
⚫ Sequence control refers to user actions and computer logic that
initiate, interrupt, or terminate transactions.
⚫ Many control applications do not involve analog process
variables.
⚫ The simplest examples of such variables are binary variables,
that can have either of two possible values, (such as 1 or 0, on
or off, open or closed etc.).
⚫ These control systems operate by turning on and off switches,
motors, valves, and other devices in response to operating
conditions and as a function of time.
⚫ Such systems are referred to as sequence/logic control systems.
Sequence Control System

Depending on the pre-specified process requirements, actuator works

automatically according to a predetermined sequence of actions under the
input signals
 Functions of sequence controller

⚫Determining the program according to production process

requirements and make the system perform process
conversion orderly.
⚫According to production process requirements, to control the
actuator and to keep process goes correctly
Types of Sequence Controllers
◆ Relay-contactor control system executed in sequence
◆ Non-contact logic control system
◆ Sequence control system which used microcomputer as the core component
◆ Programmable Logical Control(PLC)
Hardware Control System
ref: T Jagadeesha, Pneumatics, Concepts, Design, and Application
Programmable Logic Controller
ref: T Jagadeesha, Pneumatics, Concepts, Design, and Application
PLC: Advantages
ref: T Jagadeesha, Pneumatics, Concepts, Design, and Application
 Programmable Logic Control (PLC)
⚫ A PLC is an industrial computer that has been ruggedized and adapted for the control of
manufacturing processes, such as assembly lines, machines, robotic devices, or any activity that
requires high reliability, ease of programming, and process fault diagnosis.
⚫ Programmable logic controllers are intended to be used by engineers without a programming
background.
⚫ For this reason, a graphical programming language called Ladder Diagram (LD, LAD) was
first developed.
⚫ It resembles the schematic diagram of a system built with electromechanical relays and was

adopted by many manufacturers and later standardized in the IEC 61131-3 control systems
programming standard
New standards of Programming
⚫ Structured Text (ST; similar to Pascal) and Instruction List (IL); as well as
3 graphical languages: Ladder Diagram, Function Block Diagram (FBD)
and Sequential Function Chart (SFC).
⚫ PLCs use built-in ports, such as USB, Ethernet, RS-232, RS-485, or RS-
422 to communicate with external devices (sensors, actuators) and systems
(programming software, SCADA, HMI). Communication is carried over
various industrial network protocols, like Modbus, or EtherNet/IP. Many of
these protocols are vendor specific.
Features of PLC
⚫ High reliability, strong anti-jamming capability
⚫ Variable control program and good variability
⚫ Programming is simple, easy to use
⚫ Fully functional, easy to expand
⚫ Reduce design and construction time
PLC Architecture
⚫The heart of the PLC system is the CPU (Central
Processing Unit).
⚫ It is made up of a control unit and processor.
⚫The CPU control unit manages the interaction
between the various PLC hardware components
while the CPU processor handles all the number
crunching and program (eg ladder logic)
execution.
⚫Data flow is from the input devices, through
the CPU processor and then to the output devices.
⚫The CPU processor also exchanges data with
the program and data memory.
⚫Once all the data is gathered the program (eg
ladder logic) is processed in a cyclic fashion.
⚫ The resulting data flows to the output interface for
conditioning and execution of the output devices.
⚫ The CPU also controls and exchanges data with
the communication interface and devices
⚫ An addressing system is used for data organization that
is shared between the various hardware components.
⚫ A programming terminal is used to formulate the PLC
program (eg ladder logic), load the program into the
controller and monitor/control the PLC and its
program.
⚫ The power supply is responsible for supplying and
managing the power requirements of the various PLC
hardware components.
Types of PLC Architecture
⚫ The 3 distinct types of PLC architecture available for use in
industrial automation are known as fixed, modular and
distributed.
⚫ Fixed PLCs are used for smaller sized, less complex
application.
⚫ Modular PLCs are generally used for medium sized, more
complex applications.
⚫ Whereas distributed PLCs are used for large sized, extensive
application spread across multiple location.
Distributed PLC Architecture
PLC: Input scan, Program scan and Output scan
ref: T Jagadeesha, Pneumatics, Concepts, Design, and Application
PLC Programming: Ladder Diagram
ref: T Jagadeesha, Pneumatics, Concepts, Design, and Application
PLC Programming: Ladder Diagram
ref: T Jagadeesha, Pneumatics, Concepts, Design, and Application
PLC Programming: Bit Operations
ref: T Jagadeesha, Pneumatics, Concepts, Design, and Application
 PLC Programming: Timers
ref: T Jagadeesha, Pneumatics, Concepts, Design, and Application

Timers are programming elements delaying the turning on or turning off events to a
preset duration.
 PLC Programming: Counters
ref: T Jagadeesha, Pneumatics, Concepts, Design, and Application

They are used to detect workpieces, numbers and events.

Count up: Accumulator value increases by one for each transition to high state of input.
The output set when accumulator reaches preset value.
Count down: Accumulator value decreases by one for each transition to high state of
input. The output set when accumulator reaches zero value.
 PLC Programming: Memory elements
ref: T Jagadeesha, Pneumatics, Concepts, Design, and Application

■ They are used to store intermediate values.

■ It stores a set or reset condition with a space of one bit.
■ Memory address locations vary between manufacturers
■ Commercial PLCs offer bit memories in blocks of 1024, 2048,8192 etc..
Inspection Automation
■ Inspection has become an essential part of any manufacturing system. It is the means of rejecting
nonconformities and assuring good quality products. The advent of technologically updated
inspection equipment helped to overcome the problems associated with traditional approaches.
■ The term inspection can be defined as the activity of examining the products, its components,
sub-assemblies, or materials out of which it is made, and to determine whether they adhere to
design specifications. The design specifications are prescribed by the product designer.
■ Types of Inspection Classification of inspection is based on the amount of information derived
from the inspection procedure about the item’s conformance to its specifications.
 Inspection for variables, in which, appropriate measuring instruments or sensors are used to
measure one or more quality characteristics.
 Inspection for attributes, where the parts or products are inspected to conform to the inspected
quality standard. The determination is sometimes based simply on the judgement of inspector.
Attribute inspection involves counting the number of defects in a product.
Inspection Procedure

■ The steps in the inspection performed on an individual item, such as part, sub-assembly or
final product are as follows :
 Presentation The item is presented for evaluation.
 Examination The item is examined for non-conforming features. Measurement of a
dimension or other attributes of the part or product are examined, while inspecting the
variables.
 Decision: It is based on the evaluation, a decision is made whether the item adhere to the
defined quality standards. The simplest case involves a binary decision, in which the item
is deemed either acceptable or unacceptable.
 Action: Action should be taken based on the decision to accept or reject the item, or sort
the items to the most appropriate quality grade.
Inspection Accuracy

■ There are normally two errors committed on the part of manufacturers while carrying
out the inspection.
■ These two kinds of mistake are called Type I and Type II errors.
■ Type I error occurs when a good lot is rejected and is called producers risk.
■ Type II error occurs when a bad lot is accepted and is called consumers risk.
■ An error is committed by the inspector that misses some of the defect during inspection
of an assembly line.
■ The capability of the inspection process to avoid these types of errors is termed as
inspection accuracy.
AUTOMATED INSPECTION
■ Automated inspection is defined as the automation of one or more steps involved in the
inspection procedure. Automated or semi-automated inspection can be implemented in the
number of alternative ways.
 Automated presentation of parts by an automatic handling system with manual examination and
decision steps.
 Machine with manual loading parts into the machine doing, automated examination and
decision making.
 Completely automated inspection system in which parts presentation, examination and decisions
are performed automatically.
The inspection procedure is performed by a human worker in the first case, with all of the possible
errors in this form of inspection. In second and third case, the actual inspection operation is
accomplished by an automated system.
Feedback Process Control

■ In the inspection operation, data are feedback to the manufacturing process responsible
and the same is evaluated.
■ The motive behind the feedback is to allow compensating adjustments to be made in the
process to reduce variability and improve quality.
■ If the output of process starts drifting toward the high side of tolerance (e.g. tool wear
may cause a part dimension to increase over time), adjustment can be made in the input
parameters to bring the output back to the nominal value.
■ In this way, average quality is maintained within a smaller variability range than is
possible with sampling inspection methods. As a result, process capability is improved
Parts Sortation

■ Here, parts are sorted on the basis of quality level and classified as accepted or rejected
part.
■ There may be more than two levels of quality appropriate for the process (e.g.
acceptable, reworkable, and scrap).
■ Sortation and inspection may be accomplished in several ways. One alternative is to
both inspect and sort at the same station.
■ Other installation locates one or more inspections along the processing line, with a
single sortation station near the end of the line.
■ Inspection data are evaluated and inspections are put forth to the sortation station
indicating what action is required for each part.
Timing of inspection

■ An important consideration in quality control is the determination of timings of the

inspection procedure. Three different options can be identified which are :
(a) off-line inspection
(b) on-line/in-process, and
(c) on-line/post process inspection
Off-line inspection
■ In off-line inspection, the inspection equipment is usually dedicated and does not make
any physical contact with machine tools. There is always a time delay between
production and inspection.
■ Manual inspection is common that tend to promote the use of offline inspection that
include:
(i) variability of the process is well within the design tolerance,
(ii) processing conditions are stable and the risk of significant deviation in the process is
small, and
(iii) cost incurred during inspection is high in comparison to the cost of few defective parts.
The disadvantage of offline inspection is that the parts have already been made by the time
poor quality is detected. Sometimes by default a defective part may not be included into the
sample. A coordinate measuring machine (CMM) is an example of off-line inspection
On-line/In-process and On-line/Post-
process Inspection Methods
■ If the task of inspection is done as the parts are manufactured, then it is called as online
inspection. There are two variations of on-line inspection.
■ If the inspection is performed during the manufacturing operation, it is called on-line/in-
process inspection.
■ If the inspection is performed immediately following the production process, it is called
on-line/post-process inspection
■ The primary inspection elements of the probes are sensors.
■ Signals are transmitted to the controller as the contact is made with the part surface.
■ Numerous technologies are available for transmitting the signals. Some of them are
direct electrical connection, induction coil, infrared data transmission.
■ The task of the data processing and interpretation is facilitated through the controller.
COORDINATE MEASURING
MACHINE
■ The measurement of original shape and dimension of an object and their comparison
with desired shape and dimensions as described in part drawing that comes into the
broad area of Coordinate Metrology.
■ Evaluations of the location, orientation, dimension and geometry and part or the objects
are the various components of coordinate metrology.
■ A coordinate measuring machine is an electromechanical system designed to perform
coordinate metrology. A CMM consists of a contact probe, and this contact probe is
positioned in three-dimensional (3-D) spaces relative to the surface of a work-part. In
order to obtain, dimensional data pertaining to the part geometry, x, y, z coordinates of
the probe are accurately measured
■ In three-dimensional coordinate system, a basic CMM is composed of the following
components.
(i) Probe head and probe,
(ii) Mechanical structure and displacement transducer,
(iii) Drive system and control units, and
(iv) Digital computer system with application software
Constructional Details of CMM
• The construction of CMM can best be described with the help of its two basic components:
(1) Probe
(2) Mechanical structure.
Probe
• The contact probe is an important component of CMM. The probe is fastened to mechanical
structure that allows movement of probe relative to the part. When contact has been made
with part surface during measurement. The tip of the probe is made of ruby ball.
• Hardness for wear resistance and low density for minimum inertia are the required
characteristics for the application of ruby in probe. Probe is of two types (1) single tip and
(2) multiple tips .
• Touch trigger probes are most widely used probes. The probe actuates when the contact is
made with part surface
The various triggering mechanism, which are used commercially are discussed as follows.
(i) The trigger is based on the principle that, when the tip of the probe is deflected from
neutral position then the highly sensitive electrical contact switch starts emitting signal.
(ii) The trigger actuates when there is an electrical contact between probe and metallic
part surface.
(iii) The trigger uses a piezoelectric sensor that generates a signal based on tension or
compression loading of the probe.
• As contact exists between the probe and the surface of the object then with the help of
displacement transducer the coordinate position of the probe are accurately measured.
Various displacement transducers such as optical scales, rotary encoding, and magnetic
scales etc are used in CMM. Probe occupies its neutral position when it has been separate out
from the contact surface.
 Mechanical Structure
• In order to achieve the motion of the probe, various physical components are used.
Mechanical configurations of CMM are categorized into six types. Each has advantages and
disadvantages associated with them. These are :
a. Cantilever
• Such type of construction uses three movable components. These components move along
mutually perpendicular guide ways. The workpiece is supported on the worktable with the
help of CMM holding fixture.
• Three- dimensional measurements are accomplished by having the probe attached to
vertical quill, which moves vertically in the z direction relative to the horizontal arm. In order
to achieve y axis motion, the quill can also move horizontally in the y direction along the
length of the arm. The arm is supported at one end only in cantilever fashion and moves
horizontally in the x direction relative to machine base.
b. Moving Bridge
• This provides a more rigid structure than the cantilever design and give rise to more
accuracy.
• Here the probe is mounted on the bridge structure. The part, which is to be measured, is
positioned on the table and the bridge structure is moved relative to the stationary table.
• The common difficulty associated with moving bridge design is yawing (walking).
• This happens because two legs of the bridge move at slightly different speeds and resulted
in the twisting of the bridge.
• This phenomenon reduced the accuracy of the measurement. These types of designs are
most widely used in industry.
c. Fixed Bridge
• The bridge is attached to the CMM bed and worktable is moved in the x direction beneath
the bridge.
• This structure eliminates the phenomena of yawing and leads to more accuracy and more
rigidity.
• However, in this design throughput is somewhat affected due to involvement of additional
mass.
d. horizontal Arm
• Horizontal arm CMMs come in a variety of configuration such as moving ram, moving
table, and fixed table.
• These CMMs are mainly used to measure the dimensional and geometric accuracy of
the machined or fabricated work pieces
e.Gantry
• This type of construction is used for the inspection of large objects.
• It is gantry crane type of construction in which x axis motion is obtained by moving the
cross beam along two elevated rails.
• The probe quill moves vertically relative to a cross beam to obtain its axis motion.
CMM CONTROLS
• On the basis of operating and controlling of CMM, it can be classified in the four following
ways :
(i) manual drive,
(ii) manual drive with computer-assisted data processing,
iii) motor drive with computer-assisted data processing, and
(iv) DCC - direct computer control with computer-assisted data processing.
f Column
• Its construction is quite similar to that of the machine tool. The work table is used to obtain
the x axis and y axis motion. The probe quill is moved vertically to obtain z axis motion.
These machines are also referred as universal measuring machine (UMMs).
CMM Operation and Programming
• There are several ways in which the probe can be positioned that varies from manual
operation to the direct computer control (DCC).
• Computer-controlled CMMs must be programmed and they must operate similar to CNC
machine tools. In this section aspects of CMMs taken into account are :
(i) types of CMM controls; and
(ii) programming of computer-controlled CMMs.
• The probe is physically moved by human operator along the machine’s axes for making
contact with the part and the measurements are recorded in manual drive CMM.
• The three orthogonal slides are designed to be nearly frictionless to permit the probe to be
free floating in the x, y, and z-directions.
• A digital readout provides the measurements that the operator can record either manually or
with paper printout.
• Only operator is allowed to carry out calculations on the data that includes the enumeration
of the center and hole diameter.
• Data processing and computational capability for performing the calculations that are required
to evaluate a given part feature are provided by a CMM with manual drive CMM with computer-
assisted data processing.
• The different types of data processing and computations are ranging from simple conversions
between US customary units and metric to more complicated geometry calculations, such as
determining the angle between two planes.
• The probe is free floating and permits the operator to bring it into contact with the desired part
surfaces.
• Electric motors are used in a motor driven CMM with the computer-assisted data
processing to drive the probe along the machine axes under the operator control.
• The motion is controlled by joystick or similar devices. The collisions between the probe
and the part are reduced by low-power stepping motor and friction clutches.
• CMM with direct computer control (DCC) operates just like a CNC machine tool. It is power
driven and the movements of the coordinate axes are controlled by a dedicated computer
under program control. Various data processing is performed by the computer and it also
keeps record of the measurements made during inspection. DCC CMM requires a part
programming facility
Non contact Inspection Technologies
COORDINATE MEASURING MACHINE

• The measurement of original shape and dimension of an object and

their comparison with desired shape that comes into the broad area of
Coordinate Metrology.
• Evaluations of the location, orientation, dimension and geometry and
part or the objects are the various components of coordinate
metrology.
• A coordinate measuring machine is an electromechanical system
designed to perform coordinate metrology.
• A CMM consists of a contact probe, and this contact probe is
positioned in three-dimensional (3-D) spaces relative to the surface of
a work-part. In order to obtain, dimensional data pertaining to the part
geometry, x, y, z coordinates of the probe are accurately measured.
• In three-dimensional coordinate system, a basic CMM is composed of the following components.
• Probe head and probe,
• Mechanical structure and displacement transducer,
• Drive system and control units, and
• Digital computer system with application software
Constructional Details of CMM
• The construction of CMM can best be described with the help of its two basic components:
(1) Probe
(2) Mechanical structure.
Probe
■ The contact probe indicates when contact has been made with the part surface during measurement. The tip
of the probe is usually a ruby ball. Ruby is a form of corundum (aluminum oxide), whose desirable properties
in this application include high hardness for wear resistance and low density for minimum inertia.
■ Probe is of two types (1) single tip and (2) multiple tips .
■ Touch-trigger probes, which actuate when the probe makes contact with the part
surface. Commercially available touch-trigger probes utilize any of various triggering
mechanisms, including the following:
(1) a highly sensitive electrical contact switch that emits a signal when the tip of the probe
is deflected from its neutral position,
(2) a contact switch that permits actuation only when electrical contact is established
between the probe and the (metallic) part surface, or
(3) a piezoelectric sensor that generates a signal based on tension or compression loading of
the probe.
■ Immediately after contact is made between the probe and the surface of the object, the
coordinate positions of the probe are accurately measured by displacement transducers
associated with each of the three linear axes and recorded by the CMM controller. After
the probe has been separated from the contact surface, it returns to its neutral position.
The various triggering mechanism, which are used commercially are discussed as follows.
(i) The trigger is based on the principle that, when the tip of the probe is deflected from neutral
position then the highly sensitive electrical contact switch starts emitting signal.
(ii) The trigger actuates when there is an electrical contact between probe and metallic part
surface.
(iii) The trigger uses a piezoelectric sensor that generates a signal based on tension or
compression loading of the probe.
• As contact exists between the probe and the surface of the object then with the help of displacement
transducer the coordinate position of the probe are accurately measured. Various displacement
transducers such as optical scales, rotary encoding, and magnetic scales etc are used in CMM. Probe
occupies its neutral position when it has been separate out from the contact surface.
Mechanical Structure
• In order to achieve the motion of the probe, various physical components are used. Mechanical
configurations of CMM are categorized into six types. Each has advantages and disadvantages
associated with them. These are :
a. Cantilever
• Such type of construction uses three movable components. These components move along mutually
perpendicular guide ways. The workpiece is supported on the worktable with the help of CMM
holding fixture.
• Three- dimensional measurements are accomplished by having the probe attached to vertical quill,
which moves vertically in the z direction relative to the horizontal arm. In order to achieve y axis
motion, the quill can also move horizontally in the y direction along the length of the arm. The arm is
supported at one end only in cantilever fashion and moves horizontally in the x direction relative to
machine base.
b. Moving Bridge
• This provides a more rigid structure than the cantilever design and give rise to more accuracy.
• Here the probe is mounted on the bridge structure. The part, which is to be measured, is positioned
on the table and the bridge structure is moved relative to the stationary table.
• The common difficulty associated with moving bridge design is yawing (walking).
• This happens because two legs of the bridge move at slightly different speeds and resulted in the
twisting of the bridge.
• This phenomenon reduced the accuracy of the measurement. These types of designs are most
widely used in industry.
c. Fixed Bridge
• The bridge is attached to the CMM bed and worktable is moved in the x direction beneath the
bridge.
• This structure eliminates the phenomena of yawing and leads to more accuracy and more rigidity.
• However, in this design throughput is somewhat affected due to involvement of additional mass.
d. horizontal Arm
• Horizontal arm CMMs come in a variety of configuration such as moving ram, moving table,
and fixed table.
• These CMMs are mainly used to measure the dimensional and geometric accuracy of the
machined or fabricated work pieces
e.Gantry
• This type of construction is used for the inspection of large objects.
• It is gantry crane type of construction in which x axis motion is obtained by moving the cross
beam along two elevated rails.
• The probe quill moves vertically relative to a cross beam to obtain its axis motion.
CMM CONTROLS
• On the basis of operating and controlling of CMM, it can be classified in the four following ways :
(i) manual drive,
(ii) manual drive with computer-assisted data processing,
iii) motor drive with computer-assisted data processing, and
(iv) DCC - direct computer control with computer-assisted data processing.
f Column
• Its construction is quite similar to that of the machine tool. The work table is used to obtain the x
axis and y axis motion. The probe quill is moved vertically to obtain z axis motion. These machines
are also referred as universal measuring machine (UMMs).
CMM Operation and Programming
• There are several ways in which the probe can be positioned that varies from manual operation to
the direct computer control (DCC).
• Computer-controlled CMMs must be programmed and they must operate similar to CNC machine
tools. In this section aspects of CMMs taken into account are :
(i) types of CMM controls; and
(ii) programming of computer-controlled CMMs.
• The probe is physically moved by human operator along the machine’s axes for making contact
with the part and the measurements are recorded in manual drive CMM.
• The three orthogonal slides are designed to be nearly frictionless to permit the probe to be free
floating in the x, y, and z-directions.
• A digital readout provides the measurements that the operator can record either manually or with
paper printout.
• Only operator is allowed to carry out calculations on the data that includes the enumeration of the
center and hole diameter.
• Data processing and computational capability for performing the calculations that are required to
evaluate a given part feature are provided by a CMM with manual drive CMM with computer-assisted
data processing.
• The different types of data processing and computations are ranging from simple conversions
between US customary units and metric to more complicated geometry calculations, such as
determining the angle between two planes.
• The probe is free floating and permits the operator to bring it into contact with the desired part
surfaces.
• Electric motors are used in a motor driven CMM with the computer-assisted data processing to
drive the probe along the machine axes under the operator control.
• The motion is controlled by joystick or similar devices. The collisions between the probe and the
part are reduced by low-power stepping motor and friction clutches.
• CMM with direct computer control (DCC) operates just like a CNC machine tool. It is power driven
and the movements of the coordinate axes are controlled by a dedicated computer under program
control. Various data processing is performed by the computer and it also keeps record of the
measurements made during inspection. DCC CMM requires a part programming facility