Laboratory 2 : Conveyor Control Using Automation Studio
Purpose: The purpose of
this laboratory exercise is to develop a control system for a conveyor using Automation Studio. The
system will be developed using the Allen-Bradley PLC module. The
conveyor system is used to convey a two part
coating to
previously fabricated components. A timer will be incorporated to
allow ample drying between the two
layer
application. Similarly, a counter will keep track of how many
passes the component has passed under the conveying
nozzles. Finally, a simulation will be run to verify the
successful operation of the system.
Outcomes: After completing this laboratory exercise students should be able to demonstrate the following abilities and skills:
1. Demonstrate basic knowledge and application of
selected modules within the Automation Studio software suite;
2. Demonstrate skills in the use of
Automation Studio to create a PLC control
program, and link to a HMI panel;
3. Demonstrate knowledge of timers required for on-delay control within a PLC;
4. Demonstrate knowledge of counters required for tracking cycles within a PLC;
5. Demonstrate successful completion of the
laboratory exercise through a verified system simulation;
6. Demonstrate an understanding of the conveyor
control system and control through a written laboratory report.
Deliverables: The following deliverables are required for this laboratory exercise:
1. Conveyor circuit with components clearly labeled;
2. PLC program with all inputs, outputs and functions
clearly identified;
3. Internal connections of a timer and counter within the PLC program;
4. Wiring diagram showing connections of inputs, outputs,
and power source to the PLC output interface module;
5. HMI panel diagram clearly labeled;
6. Table of all tags used for the laboratory;
7. A formal written report including the following
sections:
I. Abstract (10 points)
II. Problem Statement (5 points)
III. Required System Operation (10 points)
IV. System Diagram (10 points)
V. Procedures (10 points)
VI. Results: (25 points)
A. Sequence Control Chart (5)
B. Symbols Table (5)
C. Tags Table (5)
C. Diagrams (Pneumatic circuit, PLC program, wiring
diagram, HMI panel layout) (10)
VII. System Analysis and Summary (30 points)
A. Detailed explanation of system configuration and operation;
(10)
B. Network by Network explanation of PLC program control; (15)
C. Recommendations (5)
VIII. References
System Overview: The system operation is controlled by an HMI operator interface panel. Once Automation is placed in the
simulation mode and the operator depresses the start button. The
component fixture is initially in the leftmost position
as indicated by an end of travel sensor. The conveyor should move
forward carrying the fixture and component under
the first nozzle to receive an accelerator, continue forward passing
the component under the paint nozzle until the rightmost
end of travel sensor is activated. The part will then delay for 5
seconds allowing the conveyed material to dry, and the
conveyor will reverse, thus repeating a second two part
application. A counter must be incorporated to count the number
of coats and stop after to complete two part applications
have be achieved. An assumption is made that the part is then
transferred off the line, and a new part is placed on the
conveyor. The process can then repeat for ever single, momentary
activation of the start switch.
Diagram of Completed System:
An illustration of the system
showing the HMI panel, pneumatic circuit, input wiring, PLC program,
and output wiring is shown
below.
Procedures
A. 1. Create a list on required inputs and outputs for the PLC
program. Develop a pencil and paper sketch of the PLC program and
identify the basic
components
required. Develop a symbol table with cross referencing.
2. develop a control sequence
chart showing the logical constraints. The purpose of the chart
is to provide a guide for writing the logical
programming steps. The sequence control chart could be compared
to a flow chart usage for computer programming.
3. Develop a pencil and paper
sketch of the PLC program and identify the basic components required.
B. Load the system HMI as as shown above in Automation
Studio. Follow the procedures as outlined in class lecture by
completing the following steps:
1. Using the AB-PLC
module, create the control circuit including a appropriate inputs, outputs, timer, and counter.
2. Using the JIC Electrical Control
Module, create a wiring diam for inputs and outputs as shown.
Note: The PLC CARDS function provides
for
the connection terminal blocks with addresses and LED's. Select
the INPUT card for input connections, and OUTPUT card for output
connections.
4. Using the provided HMI panel, open the HMI Module and add both
start and stop buttons. Add indicator lights to show when the conveyor
is moving
in
the forward and reverse directions. Create the control panel as shown
below.
5. Open the Variable Manager and create the appropriate TAGS:
6. Note: Internal tags
will be created automatically when components are created in Automation
Studio. An example of tags within the Variable
Manager is shown below. Your list may be somewhat different, depending
on specify names assigned at the time the tags were created.
7. Link the tags to the appropriate component as demonstrated in class.
C. Run a simulation of the project to test for
functionality. Verify that all active components are simulated
and working properly.
Run the simulation in slow motion or
"step-by-step" and observe the logical operation. Study the
system's operation until you have
a thorough understanding of how the system operates and how control is executed.
D. Using the format specified, complete a written laboratory report and submit by next class period.
