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MITSUBISHI Automatic Door Operation PLC Programming and Simulation
leigehong posted A plc and hmi english article in PLC programming learning
In this PLC program, automatic door operation is designed using PLC programming to open or close the door when detecting the object. Here the object is nothing but a car. Automatic Door Operation The below simulation shows the automatic door system operation. Inputs and Outputs Type Device No. Device name Operation Input X0 Lower limit ON when door reaches lower limit. Input X1 Upper limit ON when door reaches upper limit. Input X2 In gate sensor ON when object approaches the door. Input X3 Out sensor ON when object leaves the door. Input YO Door up Moves up when YO is ON. Output Y1 Door down Moves down when Y1 is ON. Output Y6 Light Lit when Y6 is ON. Output Y7 Buzzer Sounds when Y7 is ON (Lamp on screen is lit). Program Description As the car approaches the entrance, the door moves up. An In-gate sensor X2 is used to detect the car’s presence at the entrance. The moment the car drives through, the door moves down. An Out-gate sensor X3 is used to detect the car’s presence after crossing the door. The upward movement of the door halts when the upper limit switch (X1) gets activated. Similarly, the door’s downward motion stops when the lower limit switch (X0) gets engaged. The door remains up as long as the car is detected within the range of the entrance (In gate sensor X2) and exit (Out sensor X3). A buzzer (Y7) buzzes as a signal for the door’s movement. While the car is within the detection range, between the In gate sensor (X2) and the Out sensor (X3), a light (Y6) remains illuminated. The status of the door’s movement is indicated by the lighting or extinguishing of four indicator lamps on the control panel. Manual control of the door is possible. Buttons on the control panel can be pressed to either open (⬆Door up) or close (⬇Door down) the door. PLC Programming -
MITSUBISHI Sorting & Distribution Line PLC Programming – Advanced Logic
leikang posted A plc and hmi english article in PLC programming learning
In this advanced PLC logic, detect different part sizes and sort them as per box sizes and place them in the trays. The parts are nothing but different size boxes such as small, medium, and large. The robot places different size boxes randomly on the conveyor. Then the system detects the box size and moves to the respective conveyor and places them in the respective trays. Sorting & Distribution Line PLC Programming The below simulation shows the sorting and distribution line system operation. Inputs and Outputs Type Device No. Device name Operation Input X0 Starting point (Supply) ON when the part is detected. Input X1 Upper ON when the part is detected. Input X2 Middle ON when the part is detected. Input X3 Lower ON when the part is detected at the right end. Input X4 Sensor ON when the part is detected at the right end. Input X5 Sensor The conveyor moves forward when Y1 is ON. Input X6 Detect part ON when the part is detected in front of the pusher. Input X10 arting point (Unload) ON when the unloading robot is at the start point. Input X11 Part on table ON when the part is on the table. Input X12 Robot operation finished ON when the robot operation is finished. Output Y1 Conveyor forward The conveyor moves forward when Y2 is ON. Output Y2 Conveyor forward Moves toward the front when Y3 is ON. Output Y3 rting wing The conveyor moves forward when Y4 is ON. Output Y4 Conveyor forward The conveyor moves forward when Y5 is ON. Output Y5 Conveyor forward Extends when Y6 is ON and retracts when Y6 is OFF. The pusher cannot be stopped in the mid-stroke. Output Y6 Pusher The robot moves part to tray when Y7 is ON. A process cycle begins. Output Y7 Unload command The robot moves the part to tray when Y7 is ON. A process cycle begins. Output Y10 Red Lit when Y10 is ON. Output Y11 Green Lit when Y11 is ON. Output Y12 Yellow Lit when Y12 is ON. Program Description Initiating the push button PB1 (X20) on the control panel triggers the Supply command (Y0), thereby setting the robot in motion for moving the object. Once the robot has completed its task of moving the part and reverting to its original position, the Supply command (Y0) is deactivated. Activating the Supply command (Y0) propels the robot to provide a part. Activating the switch SW1 (X24) on the control panel instigates the conveyors to proceed forward. Conversely, deactivating the switch causes the conveyors to halt. Conveyor-carried parts of varying sizes, namely large, medium, and small, are sorted by input from the Upper (X1), Middle (X2), and Lower (X3) sensors and delivered to designated trays. Large parts are directed to the rear conveyor when the Sorting wing (Y3) on the split conveyor is activated, followed by the part being transported on the conveyor and eventually descending from the right edge. Medium parts are led to the front conveyor when the Sorting wing (Y3) on the split conveyor is deactivated and subsequently transferred to the tray by the robot. Small parts are routed to the rear conveyor upon activation of the Sorting wing (Y3) on the split conveyor. Once the Detect part sensor (X6) in the split conveyor is activated, the conveyor is brought to a halt and the part is nudged onto the tray. When the Robot detects a part on the table (X11), the Unload command (Y7) is activated. Once the robot finishes its operations, indicated by the Robot operation finished (X12) status turning on (which happens when a part is deposited on the tray), the Unload command (Y7) is deactivated. Provided the switch SW2 (X25) on the control panel remains activated, an automatic supply of a new part occurs under the following conditions: When the robot initiates the transportation of a medium part. When a small part is added to the tray, or a large part descends from the right edge of the conveyor. The display lights flash in the following manner: The red light indicates the robot is in the process of supplying a part. Green light signifies the conveyor is in motion. Yellow light is illuminated when the conveyor is at a standstill. PLC Program -
MITSUBISHI PLC Programming: Sorting and Distribution of Boxes by Height
xiangjinjiao posted A plc and hmi english article in PLC programming learning
In this PLC programming, we do sorting and distribution of boxes by height into the designated storage bins using sensors and conveyors. This PLC program distributes the specified number of parts according to their size. PLC Sorting Boxes by Height The below simulation shows the working principle of PLC logic for sorting boxes based on their height. Here we have 3 different size boxes like small, medium, and large sizes. There are three storage bins for each box size. There are three pushers and three conveyors. Each box size has one pusher and one conveyor. The robot places the boxes randomly on the conveyor. The sensors are used to detect the box’s size. The conveyors are started and stopped when the respective box size reaches there using the sensors. The respective pusher is activated and moves the respective box size to the dedicated storage bins. PLC I/O List The below table lists the inputs and outputs of this system. Type Device No. evice Name Operation Input X0 Starting point ON when the robot is at starting point. Input X1 Upper ON when the part is detected. Input X2 Middle ON when the part is detected. Input X3 Lower ON when the part is detected. Input X4 Sensor ON when the part is detected on the incline. Input X5 Sensor ON when the part is detected on the incline. Input X6 Sensor ON when the part is detected on the incline. Input X7 Sensor ON when the part is detected at the right end. Input X10 Detect part ON when the part is detected in front of the pusher. Input X11 Detect part ON when the part is detected in front of the pusher. Input X12 Detect part ON when the part is detected in front of the pusher. Output Y0 Supply command One part is supplied When Y0 is ON. A process cycle begins: Wooden part repeats in order M, S, L, M, M, L, S, S, L, L. Output Y1 Conveyor forward The conveyor moves forward when Y1 is ON. Output Y2 Conveyor forward The conveyor moves forward when Y2 is ON. Output Y3 Conveyor forward The conveyor moves forward when Y3 is ON. Output Y4 Conveyor forward The conveyor moves forward when Y4 is ON. Output Y5 Pusher Extends when Y5 is ON and retracts when Y5 is OFF. The pusher cannot be stopped in the mid-stroke. Output Y6 Pusher Extends when Y6 is ON and retracts when Y6 is OFF. The pusher cannot be stopped in the mid-stroke. Output Y7 Pusher Extends when Y7 is ON and retracts when Y7 is OFF. The pusher cannot be stopped in the mid-stroke. Program Description Programming a Programmable Logic Controller (PLC) for Box Sorting Based on Height and Component Distribution. Initiating the robot’s operation involves pressing the pushbutton PB1 (X20) located on the control panel, which activates the Robot Supply Command (Y0). The Robot Supply Command (Y0) is deactivated upon the robot completing the part movement and returning to its initial position. The Conveyor Movement Command is controlled by the Switch SW1 (X24) on the control panel. Activating the switch (turning it ON) propels the conveyor’s movement forward while deactivating it (turning it OFF) brings the conveyor to a halt. Sorting of parts, segregated into large, medium, and small sizes, is executed through the input from the Upper (X1), Middle (X2), and Lower (X3) sensors. Post-sorting, the parts are conveyed to their designated trays. The presence of a part in the pusher is identified by the activation (turning ON) of the Part Detection Sensors (X10, X11, or X12). Upon part detection, the conveyor is brought to a halt, and the detected part is displaced onto the tray. Note: The operation of the pusher is governed by the Pusher Actuation Command. Upon receiving an ON signal, the pusher fully extends, while an OFF signal causes the pusher to retract. Each tray is to contain a specific number of parts, depending on their size. Any parts exceeding these specified numbers bypass the pusher and are ejected from the conveyor at the right end. The designated number of parts per size is as follows: Large: 3 parts Medium: 2 parts Small: 2 parts PLC Ladder Logic -
MITSUBISHI PLC Based Product Sorting Machine System – Lift Control
leikang posted A plc and hmi english article in PLC programming learning
In this advanced PLC program, PLC based product sorting machine system is used to carry different products using the lift to separate the parts based on size. Here there are three positions available based on the size like small, medium, and large. The conveyors are used to transfer the products and place them on the trays. PLC Based Product Sorting Machine System The below simulation shows the PLC sorting system using the lift operation. Inputs and Outputs Type Device No. Device name Operation Input X0 Upper ON when part is detected. Input X1 Middle ON when the lift is at a lower position. Input X2 Lower ON when the part is detected. Input X3 Part on lift ON when the part is detected. Input X4 Lower lift position ON when the lift is at the middle position. Input X5 Middle lift position ON when the lift is at middle position. Input X6 Upper lift position ON when the part is on the lift. Input X10 Sensor ON when the part is detected at the left end. Input X11 Sensor ON when the part is detected at the left end. Input X12 Sensor ON when the part is detected at the right end. Input X13 Sensor ON when the part is detected at the left end. Input X14 Sensor ON when the part is detected at the right end. Input X15 Sensor ON when the lift is at the upper position. Output YO Supply command One part is supplied when YO is ON: Metal cylinder repeats in order S, L, M, L, M, S. Output Y1 Conveyor forward ON when the part is detected at the right end. Output Y2 Lift up command The lift moves up when Y2 is ON. The lift stops when Y2 is OFF. Output Y3 Lift down command The lift moves down when Y3 is ON. The lift stops when Y3 is OFF. Output Y4 Lift rotation command The conveyor moves forward when Y1 is ON. Output Y5 Lower conveyor forward Lift rotates to transfer part to conveyor when Y4 is ON. Lifts rotates back to the original position when Y4 is OFF. Output Y6 Middle conveyor forward The conveyor moves forward when Y5 is ON. Output Y7 Upper conveyor forward The conveyor moves forward when Y6 is ON. Program Description The entire system comprises two components: General Control and Lifter Management. General Control: Activating the PB1 (X20) button on the operational panel initiates the Supply command (Y0) for the hopper. Deactivating the PB1 (X20) button turns the Supply command (Y0) off. Upon activation of the Supply command (Y0), the hopper delivers a part. The conveyors initiate movement when the SW1 (X24) on the control panel is activated. Conversely, the conveyors halt movement when the SW1 (X24) is deactivated. Upon detecting a part by the sensor X10, X12, or X14 positioned to the left of the conveyor, the corresponding conveyor initiates, transporting the part to the right-end tray. Three seconds post a part passing by the sensor X11, X13, or X15 to the right of the conveyor, the conveyor halts. Parts of varying sizes (large, medium, small) on the conveyor are sorted by the inputs of the Upper (X0), Middle (X1), and Lower (X2) sensors. Lifter Management: Once the Part on the lift sensor (X3) in the lift is activated, the part is transported to one of the following conveyors based on its size: Large part: Directed to the Upper conveyor Medium part: Directed to the Medium conveyor Small part: Directed to the Lower conveyor The commands for Lifting Up (Y2) and Lifting Down (Y3) are managed based on the lift’s position, detected by the following sensors: Upper: X6 Middle: X5 Lower: X4 Upon the part’s transfer from the lift to the conveyor, the Lifter Rotation command (Y4) is initiated. Post the transfer of a part, the lift returns to its initial position and remains on standby. PLC Logic -
MITSUBISHI PLC Program for Stage Control: Curtains and Stage Elevation
leigehong posted A plc and hmi english article in PLC programming learning
The PLC program for stage control provides the opening and closing of curtains, as well as the raising and lowering of the stage. It provides two modes of operation: automatic and manual. PLC Program for Stage Control The below simulation shows the usage of PLC for stage-controlling applications. This is a utility project where we have to open and close the stage curtains automatically and also manually using push buttons. The sensors are used to detect the right and left curtains’ positions at different points. After opening the curtains, the stage will be moved up and elevated to the top position. Similarly, when the curtains are closed, the center stage will be moved down. The stage position will also be tracked using lower and upper limit sensors. PLC Devices List The below table lists the all inputs and outputs in this PLC program. Type Device No. Device name Operation Input X0 Inside (Left curtain) ON when the curtain is halfway. Input X1 ON when the curtain closes completely. ON when the curtain opens completely. Input X2 Outside (Left curtain) ON when the curtain closes completely. Input X3 Inside (Right curtain) ON when the curtain is on its half-way. Input X4 Middle (Right curtain) ON when the curtain opens completely. Input X5 Outside (Right curtain) ON when the stage reaches a lower limit. Input X6 Stage upper limit The stage moves up when Y2 is ON. The stage stops when Y2 is OFF. Input X7 Stage lower limit ON when the stage reaches the upper limit. Output Y0 Curtain open command Curtains open when Y0 is ON. Curtains stop when Y0 is OFF. Output Y1 Curtain close command Curtains close when Y1 is ON. Curtains stop when Y1 is OFF. Output Y2 Stage up The stage moves up when Y2 is ON. The stage stops when Y2 is OFF. Output Y3 Stage down The stage moves down when Y3 is ON. The stage stops when Y3 is OFF. Output Y5 Buzzer Sounds when Y5 is ON (Lamp on screen is lit). Program Description PLC program to Control stage settings including opening/closing curtains and raising/lowering the stage. The purpose of this PLC program is to facilitate control over a range of stage settings, encompassing tasks such as opening and closing curtains, as well as raising and lowering the stage itself. To accommodate different preferences and requirements, the program offers two distinct modes of operation: automatic and manual. Automatic Operation When the “Begin” pushbutton (X16) on the operation panel is pressed, a buzzer (Y5) emits a sound for a duration of 5 seconds. Note: The “Begin” pushbutton (X16) can only be activated when the curtains are closed and the stage is positioned at its lower limit. After the buzzer stops, the command to open the curtains (Y0) is activated. The curtains will continue opening until they reach their outer limits, as defined by input signals X2 and X5. Once the curtains are fully opened, the stage begins to elevate when the “Stage up” command (Y2) is activated. The stage will continue moving upward until it reaches its upper limit, as indicated by input signal X6. Pressing the “End” pushbutton (X17) on the operation panel initiates the closing of the curtains. The command to close the curtains (Y1) is activated, and the curtains will close until they reach their inner limits, defined by input signals X0 and X3. Manual Operation The following operations are only available when the automatic operation described above is not active. The curtains can be opened by pressing the “Curtain open” pushbutton (X10) on the operation panel. The curtains will stop once they reach their outer limits (X2 and X5). The curtains can be closed by pressing the “Curtain close” pushbutton (X11) on the operation panel. The curtains will continue closing until they reach their inner limits (X0 and X3). The stage can be raised by pressing the “⬆Stage up” pushbutton (X12) on the operation panel. The stage will stop once it reaches its upper limit (X6). The stage can be lowered by pressing the “⬇Stage down” pushbutton (X13) on the operation panel. The stage will stop once it reaches its lower limit (X7). The indicator lamps on the operation panel will illuminate or turn off accordingly, providing visual feedback on the status of the curtains and stage operations. PLC Programming -
MITSUBISHI Advanced PLC Conveyor Control: Forward and Reverse Rotation
leizuofa posted A plc and hmi english article in PLC programming learning
PLC Programming for Controlling Conveyor Direction: Facilitating Forward or Reverse Movement Based on Detected Part Size. Identify Each Part’s Size and Ensure its Distribution to the Designated Location. Advanced PLC Conveyor Control The hopper provides different size objects when the operator presses the pushbutton then the conveyors and sensors are used to separate the objects based on their size. A pusher is used to separate two different object sizes. The conveyor can move forward and in reverse directions to place the objects as per their dedicated storage trays. A robot is used to pick and place the objects in medium size boxes. The below simulation shows the PLC conveyor simulation with different box sizes. PLC Inputs and Outputs The below table lists the inputs and outputs of this PLC project. Type Device No. Device name Operation Input X0 Upper ON when the part is detected. Input X1 Middle ON when the part is detected. Input X2 Lower ON when the robot is at starting point. Input X3 Detect part ON when the part is detected in front of the pusher. Input X4 Starting point The conveyor moves forward when Y1 is ON. Input X5 Part on table ON when the part is on the table. Input X6 Robot operation finished ON when the part is detected on the incline. Input X7 Sensor ON when the part is detected at the right end. Input X10 Sensor ON when the part is detected at the left end. Input X11 Sensor ON when the part is detected at the right end. Input X12 Sensor ON when the robot operation is finished. Output Y0 Supply command One part is supplied when Y0 is ON: Wooden part repeats in order L, M, S, M, S, L. Output Y1 Conveyor forward The conveyor moves forward when Y2 is ON. Output Y2 Conveyor forward Extends when Y3 is ON and retracts when Y3 is OFF. The pusher cannot be stopped in the mid-stroke. Output Y3 Pusher The robot moves part to tray when Y4 is ON. A process cycle begins. Output Y4 Unload command The conveyor moves forward when Y5 is ON. Output Y5 Conveyor forward The conveyor moves backward when Y6 is ON. Output Y6 Conveyor reverse Conveyor moves backward when Y6 is ON. Program Description When the pushbutton PB1 (X20) on the control panel is pressed, it activates the Supply command (Y0) for the hopper. Once you release pushbutton PB1, the Supply command is deactivated. Whenever the Supply command is engaged, the robot dispenses a part. When the switch SW1 (X24) on the control panel is activated, the conveyors start moving forward. As soon as you deactivate SW1, the conveyors halt. The conveyors transport large, medium, and small parts, which are sorted by the Upper (X0), Middle (X1), and Lower (X2) sensors respectively, to designated trays. Large part: Directed to the lower conveyor and delivered to the tray on the right. Medium part: Transferred to the tray by the robot. Small part: Directed to the lower conveyor and delivered to the tray on the left. When the Detect part sensor (X3) is activated, the conveyor stops, and a large or small part is directed to the lower conveyor. Note: When the actuating command for the pusher is turned ON, it fully extends. When the actuating command is turned OFF, the pusher fully retracts. When the Part on the table (X5) sensor in the robot is activated, the Unload command (Y4) is engaged. When the Robot operation is finished (X6) sensor is activated (it activates when a part is placed on the tray), and the Unload command (Y4) is deactivated. As long as the switch SW2 (X25) on the control panel is ON, a new part is automatically supplied in the following scenarios: When the robot starts to handle a medium part When a small or large part is deposited into a tray PLC Programming Conveyor Forward and Reverse Rotation Control
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