MT 451L: Manufacturing Automation Lab

Lab Report No. 5A

Name Muhammad Saud Dar

Reg. ID 211277

Section BEMTS-8B

Submitted To: Mam Mahnoor Zahid

Department of Mechatronics and

Biomedical Engineering
Air University

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 Lab No.5a

Objective
To understand the operation of Timer On and simulate the given tasks in Allen Bradley
PLC.
Introduction
In this section, we will cover timers used in ladder logic programming. Timers are very
important in ladder logic programming. Timers give the precision in time. Timer ON
delay starts timing when instruction is true. Timers are used to track the time when
instructions are on or off. They could also keep track on a retentive base.
Definition
The following is a list of timer instructions:
 TON - Timer On Delay
 TOF - Timer Off Delay
 RTO - Retentive Timer

TON Timer On Delay

 Symbol

 Definition
 Count time base intervals when the instruction is true.
 The Timer On Delay instruction begins to count time base intervals when
rung conditions become true. As long as rung conditions remain true, the
timer adjust its accumulated value (ACC) each evaluation until it reaches the
preset value (PRE). The accumulated value is reset when rung conditions go
false, regardless of whether the timer has timed out.
Each Timer on Delay is made of a 3-word element.
Word 1 is the control word
 Bit 0-12: Internal Use
 Bit 13: Done (DN) this bit is on when the Accumulation value >= Preset Value
 Bit 14: Timer Timing (TT) this bit is on when the timer is timing
 Bit 15: Enabled (EN), this bit is on when the timer is energized.

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Word 2 stores the preset value. (PRE)
 The programmer specifies this value. When the accumulated time
reaches the preset value the controller sets the done bit. Usually preset value is
from 0 - 32,767
 If a timer-preset value is negative an error will occur.
Word 3 stores the accumulated value. (ACC)
 This is the time elapsed since the timer was last reset. When enabled the
timer updates this continually.
 Time Base: is the timing update interval, this can vary from 0 - 1 second.

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 IN LAB TASKS:
Exercise 1:
Design a ladder diagram for the scenario:
Output to turn on after 10s of Input goes to logic 1.
a) Input cannot turn to logic 0 within these
10s.

Simulations

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 b) Input can turn to logic 0 within these
10s.

Simulations

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Exercise 2:
Let's say we have in the field an emergency stop (push button). Once the emergency
stop is pressed, we want the siren to go on after 5 sec for 5 sec.

Simulations

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 Exercise 3: Conditional Output Control
Let’s say that we have a conveyor, siren, and 1 switch LS-01. LS-01 is at the beginning
of the conveyor. When LS-01 is ON we want a buzzer to go on for 3 seconds (Security)
and then we want to start the conveyor. When LS-01 is cleared then we want to stop the
conveyor.

Simulations

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Sources of Error

Despite the reliability of Timer On Delay (TON) in PLCs, several factors can introduce errors in its
operation:

1. Incorrect Timer Configuration

o Setting an incorrect preset value (PRE) can cause unintended delays or premature execution.
o Example: In an automated conveyor system, an incorrectly configured TON may delay the
movement of goods, affecting production efficiency.

2. Electrical Noise and Interference

o Electromagnetic interference (EMI) from nearby machinery or power surges can cause timers
to trigger unexpectedly.
o Example: In HVAC control systems, electrical noise may lead to unintended compressor
activation, causing energy inefficiency.

3. Power Fluctuations and Interruptions

o Voltage fluctuations can affect the accuracy of timers, especially in systems without
uninterruptible power supplies (UPS).
o Example: In manufacturing automation, a sudden power loss can reset a TON timer, leading to
incomplete operations.

4. Faulty PLC Hardware or Wiring Issues

o Loose connections, short circuits, or faulty I/O modules may prevent the TON timer from
functioning correctly.
o Example: In packaging plants, improper wiring may prevent a TON timer from activating a
robotic arm at the correct time.

5. Software or Logic Programming Errors

o Mistakes in ladder logic programming can cause timers to behave unpredictably.
o Example: In an automated stamping machine, a misconfigured timer may result in the stamp
activating at the wrong time, causing defects.

6. Environmental Conditions (Heat, Moisture, Dust)

o Harsh environments can degrade PLC components, affecting the performance of timers.
o Example: In oil and gas refineries, excessive heat and moisture can impact PLC operations,
leading to timer malfunctions in shutdown procedures.

Applications of Timer On Delay (TON) in PLCs with Industry Examples

1. Conveyor Belt Systems

o Used to introduce a delay before starting a conveyor after detecting an item.
o Example: In Amazon's automated warehouses, TON timers ensure a controlled delay in
conveyor movement to prevent product collisions.

2. Industrial Machine Start-Up Sequences

o Ensures that machines start in a specific sequence to prevent power surges.

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 o Example: In Siemens power plants, TON timers delay the start-up of large turbines to stabilize
voltage levels.

3. Safety Systems (Emergency Stops & Alarms)

o Delays alarm activation to allow operators time to respond before triggering emergency
shutdowns.
o Example: In automotive manufacturing (Toyota), an emergency stop button uses a 5-second
TON delay before engaging sirens.

4. HVAC and Temperature Control

o Used to regulate heating/cooling cycles for energy efficiency.
o Example: In Honeywell’s smart building solutions, TON timers delay air conditioning start-up
to prevent system overload.

5. Automated Filling and Packaging Systems

o Ensures proper time delays in filling and sealing operations.
o Example: In Nestlé food processing plants, TON timers control the delay before sealing
packages to ensure proper filling.

6. Traffic Light Control Systems

o Provides time delays between light transitions for smooth traffic flow.
o Example: In urban traffic control (Siemens Traffic Systems), TON timers manage green-to-
red light transitions to avoid abrupt stops.

Conclusion

The Timer On Delay (TON) is a fundamental function in PLC-based automation, enabling precise
timing control for industrial applications. This lab provided hands-on experience in implementing TON
timers in different automation scenarios, such as delayed outputs, emergency sirens, and conveyor
control.

Understanding the potential sources of error, such as incorrect configurations, electrical noise,
power fluctuations, faulty hardware, and software logic errors, is crucial to ensuring reliable system
performance. By applying TON timers effectively, industries can enhance automation efficiency,
improve safety, and optimize energy usage.

As industrial systems become more complex, advanced timer-based control strategies combined with
IoT-enabled PLCs and predictive maintenance will further improve automation reliability and
adaptability in smart manufacturing and process control systems.

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 ASSESSMENT RUBRIC AND GRADING OF LAB PERFORMANCE
PLO2(P1): Problem Analysis

Min.
No Progress Benchmark Basics Good Excellent Outstanding
Attributes
0 1 2 3 4 5
Can build circuit,
Can start
Cannot operate Doesn’t know Can build circuit Can built circuit, can can simulate it and
software but
Simulation simulation basics of but cannot simulate it but can analyze it
cannot complete
software software simulated. cannot analyze it. using different
circuit
tools of software.
Can provide
Can provide comprehensive
comprehensive Can provide conclusion, using
Can provide basic Can accurately
Critical analysis and comprehensive engineering
analysis and provide analysis
Analysis & No Progress conclusion with analysis, using terminologies while
conclusion of and conclusion of
Conclusion relevant engineering encompassing
task performed task performed
keywords / terminologies. objectives of the
technical terms task and future
applications

PLO 5(P3): Modern Tool Usage

No progress Min Benchmark Basics Good Excellent Outstanding
Attributes 0 1 2 3 4 5
Aware of the Aware of process
Aware of process Aware of process Aware of
Mostly unaware process but lacks but lack
and follow it and follow it. application
Apparatus of the process competency in competency in
rightly with Setup apparatus process and can
setup of setting up following setting up
error. rightly. implement it
apparatus procedure apparatus
Knows the basics
Implement IDE/ Can troubleshoot
IDE/ Logic of IDE/ Logic Cant trouble Can modify for
Does not Logic and get the right
Development Developmentand shoot the new problem
comprehend Development result
can formulate error

PLO 9(A4): Individual and Team Work

No progress Min Benchmark Basics Good Excellent Outstanding

Attributes 0 1 2 3 4 5
Does not performs Inconsistently Task performed Task performed Performs all duties
Fulfil Assigned No progress any duties performs duties that completely with accurately but assigned and
Duties assigned are assigned error not on time actively on time
Experiment
Experiments Experiment Report submitted is
Report submitted objective,
Individual Lab Report not results are accurate report is not on time and format
is not proper introduction and
Report submitted but conclusion is submitted on is perfect and
format procedure added but
not added. time. results are
results have error
accurate.

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