DEPARTMENT OF MECHANICAL ENGINEERING

INDIAN INSTITUTE OF TECHNOLOGY MADRAS

ME 7050 – CNC AND ADAPTIVE CONTROL

PROGRAMMABLE LOGIC CONTROLLERS

ASSIGNMENT

1) Study the logic ladder program in Figure 1 and answer the questions that follow:
a) Suppose input 001 is switched from OFF to ON and remains on. How will the status of output 009 be affected?

b) Suppose input 001 is then switched from ON to OFF and remains OFF. How will the status of output 009 be
affected?
001 032 009

001 032

Figure 1

2) Draw a PLC ladder logic program for the truth table given below:

3) Draw the symbol and explain the operation of each of following timed contacts of a pneumatic timer:

a) On-delay timer-NOTC contact b) On-delay timer-NCTO contact

c) Off-delay timer-NOTO contact d) Off-delay timer-NCTC contact
4) What is the common name for the logic behavior attained by the ladder logic diagram shown in Figure 2?
 I1 I2 Q
1
I1 I2

Figure 2
5) Describe the behavior of this ladder in Figure 3. What would be a good name for this circuit?

Input Timer2 Timer 1

Timer 1 Timer 2

Timer 1 Output

Figure 3
5) Devise a circuit that can be used to start a motor and then after a delay of 100s start a pump. When the motor is
switched off there should be a delay of 10 s before the pump is switched off.

6) Design a PLC program and prepare a typical I/O connection diagram and logic ladder program for the following
counter specifications:

• Counts the number of times a push button is closed.

• Decrements the accumulated value of the counter each time a second push button is closed.
• Turns on a light any time the accumulated value of the counter is less than 20.
• Turns a second light when the accumulated value of the counter is equal to or greater than 20.
• Resets the counter to zero when a selector switch is closed.

7) When a part is placed on the conveyor at position 1, and when a start button is pressed, it moves to a position 2.
Upon reaching the position 2, it stops for the stamping operation to take place. After stamping, it automatically
moves to a position 3. It stops at the position 3, where the part is removed manually from the conveyor. Assume only
one part is on the conveyor at a time. Add limit switches, interlocks, push buttons, etc. as required. If you become
stuck at the middle station, you may add a manual restart switch for this point on the conveyor.
 Figure 4

8) A wood saw, W, a fan F and a lubrication pump, P all go on when a start button is pushed. A stop button stops the
saw only. The fan is to run an additional 5 seconds to blow the chips away. The lube pump is to run for 8 seconds
after shut down of W. Additionally, if the saw has run more than one minute the fan should stay on indefinitely. The
fan may then be turned off by pushing a separate fan reset button. If the saw has run less than one minute, the
pump should go off immediately when the pump is turned off. The eight seconds time delay off does not take place
for a running time of less than one minute.

9) Draw the timing diagram for the above example. Take time on x axis and various inputs and outputs on y axis.

10) A stacking/banding system (s) requires a spacer to be inserted (I) in a stack of panels after 14 sheets are stacked.
After 14 more (28 total), the stack is to be banded (B). Add sensors and assume output devices as required. After
banding is completed, there is a two second delay for the bander to pull back. Then, an identification spray color
dot (P) is to be applied to the stack. Spray time is 4 seconds.

11) There are two feeder conveyors (F1 and F2) feeding a part onto one main conveyor (M). There is a proximity device
at the end of each feeder conveyor. The proximity device outputs are fed as pulses to counters. Each counter then
shows the count of parts being put on to the main conveyor. In addition, another proximity device at the end of the
conveyor pulses in response to parts leaving and then sends the pulses to another counter. Develop a program to
have a single register showing the number of parts on the conveyor. Assume that the register is initially set to same
count as the count of parts on conveyor.

12) Develop a control program for an automatic control of the system shown in the Figure 5.

Figure 5

13) When the button is pushed, a stacker (S) starts stacking plywood sheets at point A. Stack height is controlled by a
PLC counter function, not a height sensor. When 12 parts are stacked, the conveyor (CV) goes on and moves the
stack to point B. A sensor is used to stop the conveyor at B. At B, paint (B) is applied for 12.5 seconds. After painting
is complete, the conveyor is started manually. The conveyor then moves parts to point C. At point C, the stack stops
 automatically and the stack is removed manually. The stop button stops the process any time it is depressed.
Assume that only one stack is on the conveyor at a time. Add limit switches etc. as required.

14) Create a ladder logic diagram to control the sequence of operations given below.

• Normally open start and normally closed stop pushbuttons are used to start and stop the process
• When the start button is pressed, solenoid A energizes to start filling the tank.
• As the tank fills, the empty level sensor switch (normally open) closes
• When the tank is full, the full level sensor switch (normally closed) opens.
• When the tank is full, Solenoid A is de-energized.
• The agitate motor starts automatically and runs for 3 min to mix the liquid
• When the mixing is done, solenoid B is energized to empty the tank.
• When the tank is empty, the empty sensor switch opens to de-energize solenoid B.
• The start button is pressed to repeat the sequence
• The stop button may be pressed at anytime to halt the process.

Solenoid A

Motor

Full Tank

Sensor
Switch
Empty Tank Start/Stop

Sensor Control Box

Solenoid B
Switch

Figure 6

15) Develop a sequential function diagram to control the system shown so that the actuators perform the following
sequence shown in Figure.7.

• It starts with everything off (retracted). Closing the push button switch PB1 starts the cycle.
• Next B goes on (B+) and then when reaching full stroke it goes off again (B-)
• When B is fully retracted (off) it is switched on again.
• When B reaches its full stroke for the second time, A is switched on.
• When A reaches full stroke both cylinders are switched off together and retract together.
• The cycle stops until PB1 is pushed again.
B+ B- B+ A+ (A- B-) simultaneously,

Figure 7
16) Two motors (outputs M1 and M2) are to be controlled as follows.
• When the run switch is operated both motors must run.
• After 4 minutes motor 1 must stop.
• Motor 2 continues running for another 2 minutes and stops.
• At this point a lamp is switched on.
• After a further 90 seconds, the lamp goes off and the cycle restarts.
• If a stop switch is operated at any time, the system will continue to the end of the cycle and then stop.
Develop a PLC program to make it work.

17) Components pass along a chute and interrupt a light switch which goes low (off) each time it is interrupted. Every
time 6 components have been counted, an eject operation is used to remove the batch and the then it all starts
again. Produce a ladder logic diagram to do this operation. The counter is designated C460.