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automated carwash system

This document describes an automated car wash system designed and simulated using RSLogics 5000 PLC software. The system was divided into two zones - zone 1 for presoak, foam application, and scrubbing, and zone 2 for rinsing, waxing, and drying. Cars arrive randomly and the program can speed up operations if there is a long queue. Zone 1 performs its operations then waits for zone 2 to indicate it is ready before moving the car. Once operations in both zones are complete, the car is moved out and the number of cars washed is displayed. Challenges included understanding program scan order and adding structured text for zone 2 operations. Ladder logic diagrams show the logic for zone 1 and 2 operations

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Introduction to the automated car wash project designed using RSLOGICS 5000, including the system zones for operations.

Details the operational flow for Zone 1 (pre-soak, foam, scrub) and Zone 2 (rinse, wax, dry) including system checks and queue management.

Faced challenges understanding program scans and control shifts affecting the random car generator.

Main routine ladder diagram showcasing operations in Zone 1, including start conditions and car arrival queue.

Continues the main routine with checks for car queue management, entrance gate operation, and subroutine shifts.

Further progress on execution with sequence operations in Zone 1 and managing car movements.

Belt control logic to manage car entry and exit from Zone 1, ensuring operations run smoothly.

Subroutines for executing individual operations: presoak, foam application, and their controls.

Detailed foam application operations with timing controls based on queue status.

Scrubber operations and related controls marking the end of Zone 1.

Initiation of Zone 2 operations (rinse, wax, dry) and inter-zone communication with updates on washes.Waxes and dries operations, utilizing timers and mode checks while marking operational achievements.

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AUTOMATED CAR WASH BY- Koyya Shiva Karthik Reddy Dept. Of Electrical and Microelectronics Rochester Institute of Technology INRTODUCTION As a part of the course requirement an automated car wash system was designed On RSLOGICS 5000 taking into consideration scenarios which were close enough to real world car wash system. The entire system was divided into two zones namely zone 1 which included operations pre-soak, foam applicator and scrubbing and zone two had operations rinsing, wax applicator and drying, both the zone were implemented on two different controllers which communicated via Ethernet . The program was designed such that it can handle cars arriving at random interval and can also speed up the process of all operations in both the zones if the waiting queue was long. Most of the logics were written in ladder digrams. INPUT AND OUTPUTS USE TO SIMULATE THE OPERATIONS IN ZONES OUTPUTS Type Zone1 use Zone2 use Cylinder Entrance door Exit door Light Pre-soak operation Wax applicator Dc motor Scrubbing operation Rinse Fan Foam applicator Dryer Stepper motor Car mover Car mover DISPLAY BCD display Cars in queue waiting Cars washed INPUTS Selector switch System start Cylinder sensors Indicators Indicators UDT: UDT was made to transfer data between the zones (produced and consumed tags)  ZONE1_STATUS BOOL  SYSTEM_STATUS BOOL  MODE DINT (1 OR 2)
AOI: A random number generator was used to generate cars at random interval Structured text: “Seq_operation” in zone 2 ZONE 1 FLOW Once the system was started cars were generated at random intervals and the numbers of cars in the queue were checked to determine the mode of operation (mode 1 or mode 2 indicating normal or fast operation respectively) once the mode was decided the cars was taken in and the sequence of operations were performed and once all the operations in zone 1 were over zone1 waited for a indicator from zone 2 saying its ready before moving cars to zone2. ZONE 2 FLOW Once the car was moved to zone to it would carry out sequence of operations based on the mode received from zone 1 , and once the operations of zone 1 are over it moves the car out of the car wash and indicates it ready to except new car in into the zone. system start gate open belt control gateclose display cars waiting sequnce operations presoak foam applicator scrubber move car to zone 2
SYSTEM FLOW check status of system start zone 2 sequence operations rinse waxing drying belt contol move car out of car wash dispaly number of cars washed zone 1 zone 2
CHALLENGES The project was basically simple but the main problem I faced was to understand how the scan in the program goes on, when there is a control shift from main to subroutine and as a result of this problem I wasn’t able to use my AOI which was random car generator as I wanted it to be scanned only once every program but it used to be scanned continues and kept adding cars. LADDER LOGIC DIGRAMS Structed text zone 2 sequential operation couldn’t be added with rest of the rungs
MainRoutine - Ladder Diagram Page 1 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:32:41 PM Total number of rungs in routine: 9 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 Koyya Shiva Karthik Reddy PLC FINAL PROJECT CAR WASH SYSTEM Zone 1(Presoak, FoamApplicator , Scrubber) This rung shows the start of the entire system, when the START switch is turned on the the system is ACTIVATED and ready to start. SYSTEM_STATUS is a produced tag which is used by zone 2. 0 START <Local:5:I.Data.20> PTAG.SYSTEM_STATUS BELT_ENABLE <Local:6:O.Data.26> Koyya Shiva Karthik Reddy PLC FINAL PROJECT CAR WASH SYSTEM Zone 1(Presoak, FoamApplicator , Scrubber) This rung shows the start of the entire system, when the START switch is turned on the the system is ACTIVATED and ready to start. SYSTEM_STATUS is a produced tag which is used by zone 2. this rung shows the random arival of cars 1 PB1 <Local:5:I.Data.16> CU DN Count Up Counter CARS_WATING Preset 1000 Accum 0 CTU Move Source CARS_WATING.ACC 0 Dest CARS_IN_QUEUE 0 MOV this rung shows the random arival of cars this is the initial state or stae of the system when the START switch is closed. 2 / PTAG.SYSTEM_STATUS Z2_STATUS.0 SCRUB_OPERATION_DONE Move Source 0 Dest BELT_MOVED 0 MOV this is the initial state or stae of the system when the START switch is closed.
MainRoutine - Ladder Diagram Page 2 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:32:50 PM Total number of rungs in routine: 9 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 this rung check if there is a car waitng in the queqe and if yes determines which mode to run the system in and openes the entrace gate. MODE HERE IS A PRODUCED TAG USED BY ZONE 2. 3 PTAG.SYSTEM_STATUS Limit Test (CIRC) Low Limit 1 Test CARS_IN_QUEUE 0 High Limit 5 LIM Move Source 1 Dest PTAG.MODE 0 MOV Greater Than (A>B) Source A CARS_IN_QUEUE 0 Source B 5 GRT Move Source 2 Dest PTAG.MODE 0 MOV Equal Source A BELT_MOVED 0 Source B 0 EQU ENTRANCE_GATE_OPEN <Local:6:O.Data.16> this rung check if there is a car waitng in the queqe and if yes determines which mode to run the system in and openes the entrace gate. MODE HERE IS A PRODUCED TAG USED BY ZONE 2. as soon as the agte is open the control shifts to the belt which moves the car into zone 1 4 GATE_OPEN_SENSOR <Local:5:I.Data.24> Move Source 1 Dest STEPS_COUNTERS.PRE 0 MOV Jump To Subroutine Routine Name BELT_CONTROL JSR as soon as the agte is open the control shifts to the belt which moves the car into zone 1 as soon as thecar is moved into zone 1 by the belt the entrance gate is closed. 5 / ENTRANCE_GATE_OPEN <Local:6:O.Data.16> Equal Source A BELT_MOVED 0 Source B 1 EQU / PTAG.SYSTEM_STATUS ENTRANCE_GATE_CLOSE <Local:6:O.Data.17> as soon as thecar is moved into zone 1 by the belt the entrance gate is closed.
MainRoutine - Ladder Diagram Page 3 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:32:52 PM Total number of rungs in routine: 9 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 as soon as the gate is closed the required sequence of operations in zone 1 are performed. 6 GATE_CLOSE_SENSOR <Local:5:I.Data.25> Subtract Source A CARS_IN_QUEUE 0 Source B 1 Dest CARS_IN_QUEUE 0 SUB Jump To Subroutine Routine Name SEQ_OPERATIONS JSR as soon as the gate is closed the required sequence of operations in zone 1 are performed. This is essentilly a display which shows the number of cars waiting in the queue 7 To BCD Source CARS_IN_QUEUE 0 Dest DISPLAY 0 TOD Masked Move Source DISPLAY 0 Mask MASK 2#0000_0000_0000_0000_1111_1111_1111_1111 Dest CARS_WAITING 0 MVM This is essentilly a display which shows the number of cars waiting in the queue once the zone 1 operation is donezone 1 waiys for aindication from one 2 indicationg is ready to exept a car and if it recives that indicator it moves the belt to move the car into zone 2 8 Equal Source A WHICH_STAGE 0 Source B 4 EQU INDICATING_ZONE2_STATUS.0 Jump To Subroutine Routine Name BELT_CONTROL JSR once the zone 1 operation is donezone 1 waiys for aindication from one 2 indicationg is ready to exept a car and if it recives that indicator it moves the belt to move the car into zone 2 (End)
BELT_CONTROL - Ladder Diagram Page 1 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:35:14 PM Total number of rungs in routine: 7 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 thsi is belt control which eentally moves the car into zone 1 and out of zone 1 when all operations in zone 1 are done. 0 PULSE_OFF_TIME.DN CU DN Count Up Counter STEPS_COUNTERS Preset 0 Accum 0 CTU thsi is belt control which eentally moves the car into zone 1 and out of zone 1 when all operations in zone 1 are done. rungs 1 2 3 4 are essentally providing necessary logics for belt to move . 1 PTAG.SYSTEM_STATUS / PULSE_OFF_TIME.DN Greater Than (A>B) Source A STEPS_COUNTERS.PRE 0 Source B 0 GRT / STEPS_COUNTERS.DN EN DN Timer On Delay Timer PULSE_ON_TIME Preset 2000 Accum 0 TON rungs 1 2 3 4 are essentally providing necessary logics for belt to move . 2 PULSE_ON_TIME.DN EN DN Timer On Delay Timer PULSE_OFF_TIME Preset 2000 Accum 0 TON 3 PULSE_ON_TIME.TT / STEPS_COUNTERS.DN BELT <Local:6:O.Data.29> 4 PULSE_OFF_TIME.DN Move Source 1 Dest BELT_MOVED 0 MOV 5 / PTAG.SYSTEM_STATUS RES STEPS_COUNTERS WHEN ZONE 1 OPERATION IS DONE A INDICATIONIS SEND TO ZONE 2 6 Equal Source A WHICH_STAGE 0 Source B 4 EQU PULSE_OFF_TIME.DN PTAG.ZONE1_STATUS WHEN ZONE 1 OPERATION IS DONE A INDICATIONIS SEND TO ZONE 2 (End)
SEQ_OPERATIONS - Ladder Diagram Page 1 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:36:06 PM Total number of rungs in routine: 4 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 this subroutie callsother sub routiens which carry out the required actions in zone 1 0 Jump To Subroutine Routine Name PRESOAK Input Par PTAG.MODE JSR this subroutie callsother sub routiens which carry out the required actions in zone 1 1 PRESOAK_OPERATION_DONE Jump To Subroutine Routine Name FOAM_APPLICATOR Input Par PTAG.MODE JSR 2 FOAM_OPERATION_DONE Jump To Subroutine Routine Name SCRUBBER Input Par PTAG.MODE JSR ONCE ZONE 1 OPERATIONS ARE COMPLETED system is ready to except new car in zone one and after it moves current car in zone 1 3 SCRUB_OPERATION_DONE Move Source 0 Dest BELT_MOVED 0 MOV Move Source 4 Dest WHICH_STAGE 0 MOV ONCE ZONE 1 OPERATIONS ARE COMPLETED system is ready to except new car in zone one and after it moves current car in zone 1 (End)
PRESOAK - Ladder Diagram Page 1 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:44:17 PM Total number of rungs in routine: 9 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 this routine carries out the presoak operation the rungs 1 and 2 set the required speed based upon the mode( number of cars waiting in the queue) 0 Equal Source A PTAG.MODE 0 Source B 1 EQU Move Source 1500 Dest M1_PRESOAK_T2.PRE 0 MOV Move Source 1500 Dest M1_PRESOAK_T1.PRE 0 MOV this routine carries out the presoak operation the rungs 1 and 2 set the required speed based upon the mode( number of cars waiting in the queue) 1 Equal Source A PTAG.MODE 0 Source B 2 EQU Move Source 1000 Dest M2_PRESOAK_T1.PRE 0 MOV Move Source 1000 Dest M2_PRESOAK_T2.PRE 0 MOV the rungs 2-7 controls the presoak oepration with help of couple of timers 2 M1_PRESOAK_T2.DN M2_PRESOAK_T2.DN CU DN Count Up Counter NO_OF_PRESOAK Preset 5 Accum 0 CTU the rungs 2-7 controls the presoak oepration with help of couple of timers 3 PTAG.SYSTEM_STATUS Equal Source A PTAG.MODE 0 Source B 1 EQU / M1_PRESOAK_T2.DN GATE_CLOSE_SENSOR <Local:5:I.Data.25> EN DN Timer On Delay Timer M1_PRESOAK_T1 Preset 0 Accum 0 TON
PRESOAK - Ladder Diagram Page 2 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:44:21 PM Total number of rungs in routine: 9 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 4 M1_PRESOAK_T1.DN EN DN Timer On Delay Timer M1_PRESOAK_T2 Preset 0 Accum 0 TON 5 PTAG.SYSTEM_STATUS Equal Source A PTAG.MODE 0 Source B 2 EQU / M2_PRESOAK_T2.DN GATE_CLOSE_SENSOR <Local:5:I.Data.25> EN DN Timer On Delay Timer M2_PRESOAK_T1 Preset 0 Accum 0 TON 6 M2_PRESOAK_T1.DN EN DN Timer On Delay Timer M2_PRESOAK_T2 Preset 0 Accum 0 TON 7 M1_PRESOAK_T1.DN / M1_PRESOAK_T2.DN M2_PRESOAK_T1.DN / M2_PRESOAK_T2.DN / NO_OF_PRESOAK.DN PRESOAK_RUNNING <Local:6:O.Data.27> 8 NO_OF_PRESOAK.DN PRESOAK_OPERATION_DONE (End)
FOAM_APPLICATOR - Ladder Diagram Page 1 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:44:51 PM Total number of rungs in routine: 5 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 THSI ROUTIE CARRY OUT THE FOAM APPLICAATION OERATION BASED ON THE MODE AND ONCE THE OERATION IS DONE ITS INDICATED FOR THE NEXT ZONE 0 PTAG.SYSTEM_STATUS / PULSE_OFF_TIME.DN / STEPS_COUNTERS.DN EN DN Timer On Delay Timer PULSE_ON_TIME Preset 2000 Accum 0 TON THSI ROUTIE CARRY OUT THE FOAM APPLICAATION OERATION BASED ON THE MODE AND ONCE THE OERATION IS DONE ITS INDICATED FOR THE NEXT ZONE 1 PTAG.SYSTEM_STATUS Equal Source A PTAG.MODE 0 Source B 1 EQU Move Source 8000 Dest M1_FOAM_DURATION.PRE 0 MOV PRESOAK_OPERATION_DONE EN DN Timer On Delay Timer M1_FOAM_DURATION Preset 0 Accum 0 TON 2 PTAG.SYSTEM_STATUS Equal Source A PTAG.MODE 0 Source B 2 EQU Move Source 5000 Dest M2_FOAM_DURATION.PRE 0 MOV PRESOAK_OPERATION_DONE EN DN Timer On Delay Timer M2_FOAM_DURATION Preset 0 Accum 0 TON 3 M1_FOAM_DURATION.TT M2_FOAM_DURATION.TT FOAM_APPLICATOR_RUNNING <Local:6:O.Data.18> 4 M1_FOAM_DURATION.DN M2_FOAM_DURATION.DN FOAM_OPERATION_DONE
FOAM_APPLICATOR - Ladder Diagram Page 2 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:44:54 PM Total number of rungs in routine: 5 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 (End)
SCRUBBER - Ladder Diagram Page 1 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:45:30 PM Total number of rungs in routine: 10 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 THIS ZONE CARRYS OUT THE SCRUBBING OPERATION AND ONCE THIS OPERATION IS DONE IT MARKS THE END OF ZONE ONE OPERATION AND WAIT AND MAKES THE WHICH SATE WHICH INDICATES THE END OF ZONE 1 0 M2_SCRUB_T2.DN M1_SCRUB_T2.DN CU DN Count Up Counter NO_OF_SCRUBS Preset 5 Accum 0 CTU THIS ZONE CARRYS OUT THE SCRUBBING OPERATION AND ONCE THIS OPERATION IS DONE IT MARKS THE END OF ZONE ONE OPERATION AND WAIT AND MAKES THE WHICH SATE WHICH INDICATES THE END OF ZONE 1 1 Equal Source A PTAG.MODE 0 Source B 1 EQU Move Source 2000 Dest M1_SCRUB_T1.PRE 0 MOV Move Source 2000 Dest M1_SCRUB_T2.PRE 0 MOV 2 Equal Source A PTAG.MODE 0 Source B 2 EQU Move Source 1000 Dest M2_SCRUB_T1.PRE 0 MOV Move Source 1000 Dest M2_SCRUB_T2.PRE 0 MOV 3 PTAG.SYSTEM_STATUS / NO_OF_SCRUBS.DN Equal Source A PTAG.MODE 0 Source B 1 EQU / M1_SCRUB_T2.DN FOAM_OPERATION_DONE EN DN Timer On Delay Timer M1_SCRUB_T1 Preset 0 Accum 0 TON 4 M1_SCRUB_T1.DN EN DN Timer On Delay Timer M1_SCRUB_T2 Preset 0 Accum 0 TON
SCRUBBER - Ladder Diagram Page 2 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:45:34 PM Total number of rungs in routine: 10 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 5 PTAG.SYSTEM_STATUS / NO_OF_SCRUBS.DN Equal Source A PTAG.MODE 0 Source B 2 EQU / M2_SCRUB_T2.DN FOAM_OPERATION_DONE EN DN Timer On Delay Timer M2_SCRUB_T1 Preset 0 Accum 0 TON 6 M2_SCRUB_T1.DN EN DN Timer On Delay Timer M2_SCRUB_T2 Preset 0 Accum 0 TON 7 M1_SCRUB_T1.TT M2_SCRUB_T1.TT / PTAG.SYSTEM_STATUS SCRUB_ACTION_1 <Local:6:O.Data.30> 8 M1_SCRUB_T2.TT / PTAG.SYSTEM_STATUS M2_SCRUB_T2.TT SCRUB_ACTION2 <Local:6:O.Data.31> 9 NO_OF_SCRUBS.DN SCRUB_OPERATION_DONE (End)
MainRoutine - Ladder Diagram Page 1 PCL_CAR_WASH_PROJECT_ZONE2:MainTask:MainProgram 12/12/2015 10:50:24 PM Total number of rungs in routine: 8 C:Userskxr3779DocumentsPCL_CAR_WASH_PROJECT_ZONE2.ACD RSLogix 5000 Koyya Shiva Karthik Reddy ZONE2 (Rinse , Wax Applicator, Dryer) this run recives system status and the status of zone one itself to start sone 2. 0 CTAG.SYSTEM_STATUS CTAG.ZONE1_STATUS / ZONE2_STATUS.0 ZONE2_IN_OPERATION.0 Koyya Shiva Karthik Reddy ZONE2 (Rinse , Wax Applicator, Dryer) this run recives system status and the status of zone one itself to start sone 2. as zone 2 starts sequence of opeartions are done. THE seq_operation is in structured text language. 1 ZONE2_IN_OPERATION.0 Jump To Subroutine Routine Name seq_operation JSR as zone 2 starts sequence of opeartions are done. THE seq_operation is in structured text language. once all operations of the zone 2 are done the exit gate is opened and car is moved out and and exit gate is then closed (indicated in rungs 2 3 4 ) 2 DRYING_OPERATION_DONE EXIT_GATE_OPEN <Local:6:O.Data.16> once all operations of the zone 2 are done the exit gate is opened and car is moved out and and exit gate is then closed (indicated in rungs 2 3 4 ) 3 GATE_OPENED <Local:5:I.Data.24> Jump To Subroutine Routine Name BELT_CONTROL JSR 4 / CTAG.SYSTEM_STATUS Equal Source A BELT_MOVED 0 Source B 1 EQU CLOSE_EXIT_GATE <Local:6:O.Data.17> as zone 2 c ar is movedout its sends a incicator to zone 1 that it is reay to except new car into zone 2. and also it dispalys the cars washed ( indicated in rungs 5-end) 5 GATE_CLOSED <Local:5:I.Data.20> ZONE2_STATUS.0 CU DN Count Up Counter NUMBER_OF_CARS_WASHED Preset 10000 Accum 0 CTU as zone 2 c ar is movedout its sends a incicator to zone 1 that it is reay to except new car into zone 2. and also it dispalys the cars washed ( indicated in rungs 5-end)
MainRoutine - Ladder Diagram Page 2 PCL_CAR_WASH_PROJECT_ZONE2:MainTask:MainProgram 12/12/2015 10:50:28 PM Total number of rungs in routine: 8 C:Userskxr3779DocumentsPCL_CAR_WASH_PROJECT_ZONE2.ACD RSLogix 5000 6 To BCD Source NUMBER_OF_CARS_WASHED.ACC 0 Dest DISPLAY 0 TOD Masked Move Source DISPLAY 0 Mask MASK 2#0000_0000_0000_0000_0000_0000_0000_0000 Dest CARS_WASHED <Local:6:O.Data> 0 MVM 7 / CTAG.SYSTEM_STATUS Masked Move Source 0 Mask MASK 2#0000_0000_0000_0000_0000_0000_0000_0000 Dest CARS_WASHED <Local:6:O.Data> 0 MVM (End)
BELT_CONTROL - Ladder Diagram Page 1 PCL_CAR_WASH_PROJECT_ZONE2:MainTask:MainProgram 12/12/2015 10:50:49 PM Total number of rungs in routine: 5 C:Userskxr3779DocumentsPCL_CAR_WASH_PROJECT_ZONE2.ACD RSLogix 5000 his routie controls the moment of car outside the car wash by controlling the belt movement 0 PULSE_OFF_TIME.DN CU DN Count Up Counter STEPS_COUNTERS Preset 0 Accum 1 CTU his routie controls the moment of car outside the car wash by controlling the belt movement 1 / PULSE_OFF_TIME.DN EN DN Timer On Delay Timer PULSE_ON_TIME Preset 1000 Accum 0 TON 2 PULSE_ON_TIME.DN EN DN Timer On Delay Timer PULSE_OFF_TIME Preset 1000 Accum 0 TON 3 ZONE2_IN_OPERATION.0 PULSE_ON_TIME.TT / STEPS_COUNTERS.DN BELT <Local:6:O.Data.29> 4 PULSE_OFF_TIME.DN Move Source 1 Dest BELT_MOVED 0 MOV (End)
SEQ_OPERATIONS - Ladder Diagram Page 1 PCL_CAR_WASH_PROJECT_ZONE2:MainTask:MainProgram 12/12/2015 10:51:30 PM Total number of rungs in routine: 3 C:Userskxr3779DocumentsPCL_CAR_WASH_PROJECT_ZONE2.ACD RSLogix 5000 this subroutine call all other sub routies to perform the required sequense of operations 0 Jump To Subroutine Routine Name RINSE JSR this subroutine call all other sub routies to perform the required sequense of operations 1 RINSE_DONE Jump To Subroutine Routine Name WAX_APPLICATOR JSR 2 WAXING_OPERATION_DONE Jump To Subroutine Routine Name DRYER Input Par PTAG.MODE JSR (End)
RINSE - Ladder Diagram Page 1 PCL_CAR_WASH_PROJECT_ZONE2:MainTask:MainProgram 12/12/2015 10:55:13 PM Total number of rungs in routine: 10 C:Userskxr3779DocumentsPCL_CAR_WASH_PROJECT_ZONE2.ACD RSLogix 5000 THIS routine controls the rinsing operation and as soon as the operation is done it indicats that its done rinsing 0 M2_RINSE_T2.DN M1_RINSE_T2.DN CU DN Count Up Counter NO_OF_RINSE_CYCLE Preset 5 Accum 0 CTU THIS routine controls the rinsing operation and as soon as the operation is done it indicats that its done rinsing 1 Equal Source A CTAG.MODE 0 Source B 1 EQU Move Source 5000 Dest M1_RINSE_T1.PRE 0 MOV Move Source 5000 Dest M1_RINSE_T2.PRE 0 MOV 2 Equal Source A CTAG.MODE 0 Source B 2 EQU Move Source 3000 Dest M2_RINSE_T1.PRE 0 MOV Move Source 3000 Dest M2_RINSE_T2.PRE 0 MOV 3 / NO_OF_RINSE_CYCLE.DN Equal Source A CTAG.MODE 0 Source B 1 EQU / M1_RINSE_T2.DN EN DN Timer On Delay Timer M1_RINSE_T1 Preset 0 Accum 0 TON 4 M1_RINSE_T1.DN EN DN Timer On Delay Timer M1_RINSE_T2 Preset 0 Accum 0 TON 5 / NO_OF_RINSE_CYCLE.DN Equal Source A CTAG.MODE 0 Source B 2 EQU / M2_RINSE_T2.DN EN DN Timer On Delay Timer M2_RINSE_T1 Preset 0 Accum 0 TON
RINSE - Ladder Diagram Page 2 PCL_CAR_WASH_PROJECT_ZONE2:MainTask:MainProgram 12/12/2015 10:55:17 PM Total number of rungs in routine: 10 C:Userskxr3779DocumentsPCL_CAR_WASH_PROJECT_ZONE2.ACD RSLogix 5000 6 M2_RINSE_T1.DN EN DN Timer On Delay Timer M2_RINSE_T2 Preset 0 Accum 0 TON 7 ZONE2_IN_OPERATION.0 M1_RINSE_T1.TT M2_RINSE_T1.TT RINSE_ACTION1 <Local:6:O.Data.30> 8 ZONE2_IN_OPERATION.0 M1_RINSE_T2.TT M2_RINSE_T2.TT RINSE_ACTION2 <Local:6:O.Data.31> 9 NO_OF_RINSE_CYCLE.DN RINSE_DONE (End)
WAX_APPLICATOR - Ladder Diagram Page 1 PCL_CAR_WASH_PROJECT_ZONE2:MainTask:MainProgram 12/12/2015 10:55:48 PM Total number of rungs in routine: 9 C:Userskxr3779DocumentsPCL_CAR_WASH_PROJECT_ZONE2.ACD RSLogix 5000 this routie controls the waxing operation and once its done waxing it indicates that its done waxing. 0 Equal Source A CTAG.MODE 0 Source B 1 EQU Move Source 1500 Dest M1_WAX_T1.PRE 0 MOV Move Source 1500 Dest M1_WAX_T2.PRE 0 MOV this routie controls the waxing operation and once its done waxing it indicates that its done waxing. 1 Equal Source A CTAG.MODE 0 Source B 2 EQU Move Source 1000 Dest M2_WAX_T1.PRE 0 MOV Move Source 1000 Dest M2_WAX_T2.PRE 0 MOV 2 M1_WAX_T2.DN M2_WAX_T2.DN CU DN Count Up Counter WAX_APPLICATOR_COUNTER Preset 5 Accum 0 CTU 3 Equal Source A CTAG.MODE 0 Source B 1 EQU / M1_WAX_T2.DN RINSE_DONE EN DN Timer On Delay Timer M1_WAX_T1 Preset 0 Accum 0 TON 4 M1_WAX_T1.DN EN DN Timer On Delay Timer M1_WAX_T2 Preset 0 Accum 0 TON 5 Equal Source A CTAG.MODE 0 Source B 2 EQU / M2_WAX_T2.DN RINSE_DONE EN DN Timer On Delay Timer M2_WAX_T1 Preset 0 Accum 0 TON 6 M2_WAX_T1.DN EN DN Timer On Delay Timer M2_WAX_T2 Preset 0 Accum 0 TON 7 ZONE2_IN_OPERATION.0 M1_WAX_T1.DN / M1_WAX_T2.DN M2_WAX_T1.DN / M2_WAX_T2.DN WAX_APPLICATOR_RUNNIMG <Local:6:O.Data.27>
WAX_APPLICATOR - Ladder Diagram Page 2 PCL_CAR_WASH_PROJECT_ZONE2:MainTask:MainProgram 12/12/2015 10:55:53 PM Total number of rungs in routine: 9 C:Userskxr3779DocumentsPCL_CAR_WASH_PROJECT_ZONE2.ACD RSLogix 5000 8 WAX_APPLICATOR_COUNTER.DN WAXING_OPERATION_DONE (End)
DRYER - Ladder Diagram Page 1 PCL_CAR_WASH_PROJECT_ZONE2:MainTask:MainProgram 12/12/2015 10:57:03 PM Total number of rungs in routine: 4 C:Userskxr3779DocumentsPCL_CAR_WASH_PROJECT_ZONE2.ACD RSLogix 5000 THIS routine controls the drying operation and the duration based on mode and indicated once the drying operation is done 0 Equal Source A CTAG.MODE 0 Source B 1 EQU Move Source 10000 Dest M1_DRYER_DURATION.PRE 0 MOV / M1_DRYER_DURATION.DN WAXING_OPERATION_DONE EN DN Timer On Delay Timer M1_DRYER_DURATION Preset 0 Accum 0 TON THIS routine controls the drying operation and the duration based on mode and indicated once the drying operation is done 1 Equal Source A CTAG.MODE 0 Source B 2 EQU Move Source 5000 Dest M2_DRYER_DURATION.PRE 0 MOV / M2_FOAM_DURATION.DN WAXING_OPERATION_DONE EN DN Timer On Delay Timer M2_DRYER_DURATION Preset 0 Accum 0 TON 2 ZONE2_IN_OPERATION.0 M1_DRYER_DURATION.TT M2_DRYER_DURATION.TT DRYER_RUNNING <Local:6:O.Data.18> 3 M1_DRYER_DURATION.DN M2_DRYER_DURATION.DN DRYING_OPERATION_DONE (End)

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automated carwash system

  • 1.
    AUTOMATED CAR WASH BY-Koyya Shiva Karthik Reddy Dept. Of Electrical and Microelectronics Rochester Institute of Technology INRTODUCTION As a part of the course requirement an automated car wash system was designed On RSLOGICS 5000 taking into consideration scenarios which were close enough to real world car wash system. The entire system was divided into two zones namely zone 1 which included operations pre-soak, foam applicator and scrubbing and zone two had operations rinsing, wax applicator and drying, both the zone were implemented on two different controllers which communicated via Ethernet . The program was designed such that it can handle cars arriving at random interval and can also speed up the process of all operations in both the zones if the waiting queue was long. Most of the logics were written in ladder digrams. INPUT AND OUTPUTS USE TO SIMULATE THE OPERATIONS IN ZONES OUTPUTS Type Zone1 use Zone2 use Cylinder Entrance door Exit door Light Pre-soak operation Wax applicator Dc motor Scrubbing operation Rinse Fan Foam applicator Dryer Stepper motor Car mover Car mover DISPLAY BCD display Cars in queue waiting Cars washed INPUTS Selector switch System start Cylinder sensors Indicators Indicators UDT: UDT was made to transfer data between the zones (produced and consumed tags)  ZONE1_STATUS BOOL  SYSTEM_STATUS BOOL  MODE DINT (1 OR 2)
  • 2.
    AOI: A randomnumber generator was used to generate cars at random interval Structured text: “Seq_operation” in zone 2 ZONE 1 FLOW Once the system was started cars were generated at random intervals and the numbers of cars in the queue were checked to determine the mode of operation (mode 1 or mode 2 indicating normal or fast operation respectively) once the mode was decided the cars was taken in and the sequence of operations were performed and once all the operations in zone 1 were over zone1 waited for a indicator from zone 2 saying its ready before moving cars to zone2. ZONE 2 FLOW Once the car was moved to zone to it would carry out sequence of operations based on the mode received from zone 1 , and once the operations of zone 1 are over it moves the car out of the car wash and indicates it ready to except new car in into the zone. system start gate open belt control gateclose display cars waiting sequnce operations presoak foam applicator scrubber move car to zone 2
  • 3.
    SYSTEM FLOW check statusof system start zone 2 sequence operations rinse waxing drying belt contol move car out of car wash dispaly number of cars washed zone 1 zone 2
  • 4.
    CHALLENGES The project wasbasically simple but the main problem I faced was to understand how the scan in the program goes on, when there is a control shift from main to subroutine and as a result of this problem I wasn’t able to use my AOI which was random car generator as I wanted it to be scanned only once every program but it used to be scanned continues and kept adding cars. LADDER LOGIC DIGRAMS Structed text zone 2 sequential operation couldn’t be added with rest of the rungs
  • 5.
    MainRoutine - LadderDiagram Page 1 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:32:41 PM Total number of rungs in routine: 9 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 Koyya Shiva Karthik Reddy PLC FINAL PROJECT CAR WASH SYSTEM Zone 1(Presoak, FoamApplicator , Scrubber) This rung shows the start of the entire system, when the START switch is turned on the the system is ACTIVATED and ready to start. SYSTEM_STATUS is a produced tag which is used by zone 2. 0 START <Local:5:I.Data.20> PTAG.SYSTEM_STATUS BELT_ENABLE <Local:6:O.Data.26> Koyya Shiva Karthik Reddy PLC FINAL PROJECT CAR WASH SYSTEM Zone 1(Presoak, FoamApplicator , Scrubber) This rung shows the start of the entire system, when the START switch is turned on the the system is ACTIVATED and ready to start. SYSTEM_STATUS is a produced tag which is used by zone 2. this rung shows the random arival of cars 1 PB1 <Local:5:I.Data.16> CU DN Count Up Counter CARS_WATING Preset 1000 Accum 0 CTU Move Source CARS_WATING.ACC 0 Dest CARS_IN_QUEUE 0 MOV this rung shows the random arival of cars this is the initial state or stae of the system when the START switch is closed. 2 / PTAG.SYSTEM_STATUS Z2_STATUS.0 SCRUB_OPERATION_DONE Move Source 0 Dest BELT_MOVED 0 MOV this is the initial state or stae of the system when the START switch is closed.
  • 6.
    MainRoutine - LadderDiagram Page 2 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:32:50 PM Total number of rungs in routine: 9 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 this rung check if there is a car waitng in the queqe and if yes determines which mode to run the system in and openes the entrace gate. MODE HERE IS A PRODUCED TAG USED BY ZONE 2. 3 PTAG.SYSTEM_STATUS Limit Test (CIRC) Low Limit 1 Test CARS_IN_QUEUE 0 High Limit 5 LIM Move Source 1 Dest PTAG.MODE 0 MOV Greater Than (A>B) Source A CARS_IN_QUEUE 0 Source B 5 GRT Move Source 2 Dest PTAG.MODE 0 MOV Equal Source A BELT_MOVED 0 Source B 0 EQU ENTRANCE_GATE_OPEN <Local:6:O.Data.16> this rung check if there is a car waitng in the queqe and if yes determines which mode to run the system in and openes the entrace gate. MODE HERE IS A PRODUCED TAG USED BY ZONE 2. as soon as the agte is open the control shifts to the belt which moves the car into zone 1 4 GATE_OPEN_SENSOR <Local:5:I.Data.24> Move Source 1 Dest STEPS_COUNTERS.PRE 0 MOV Jump To Subroutine Routine Name BELT_CONTROL JSR as soon as the agte is open the control shifts to the belt which moves the car into zone 1 as soon as thecar is moved into zone 1 by the belt the entrance gate is closed. 5 / ENTRANCE_GATE_OPEN <Local:6:O.Data.16> Equal Source A BELT_MOVED 0 Source B 1 EQU / PTAG.SYSTEM_STATUS ENTRANCE_GATE_CLOSE <Local:6:O.Data.17> as soon as thecar is moved into zone 1 by the belt the entrance gate is closed.
  • 7.
    MainRoutine - LadderDiagram Page 3 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:32:52 PM Total number of rungs in routine: 9 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 as soon as the gate is closed the required sequence of operations in zone 1 are performed. 6 GATE_CLOSE_SENSOR <Local:5:I.Data.25> Subtract Source A CARS_IN_QUEUE 0 Source B 1 Dest CARS_IN_QUEUE 0 SUB Jump To Subroutine Routine Name SEQ_OPERATIONS JSR as soon as the gate is closed the required sequence of operations in zone 1 are performed. This is essentilly a display which shows the number of cars waiting in the queue 7 To BCD Source CARS_IN_QUEUE 0 Dest DISPLAY 0 TOD Masked Move Source DISPLAY 0 Mask MASK 2#0000_0000_0000_0000_1111_1111_1111_1111 Dest CARS_WAITING 0 MVM This is essentilly a display which shows the number of cars waiting in the queue once the zone 1 operation is donezone 1 waiys for aindication from one 2 indicationg is ready to exept a car and if it recives that indicator it moves the belt to move the car into zone 2 8 Equal Source A WHICH_STAGE 0 Source B 4 EQU INDICATING_ZONE2_STATUS.0 Jump To Subroutine Routine Name BELT_CONTROL JSR once the zone 1 operation is donezone 1 waiys for aindication from one 2 indicationg is ready to exept a car and if it recives that indicator it moves the belt to move the car into zone 2 (End)
  • 8.
    BELT_CONTROL - LadderDiagram Page 1 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:35:14 PM Total number of rungs in routine: 7 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 thsi is belt control which eentally moves the car into zone 1 and out of zone 1 when all operations in zone 1 are done. 0 PULSE_OFF_TIME.DN CU DN Count Up Counter STEPS_COUNTERS Preset 0 Accum 0 CTU thsi is belt control which eentally moves the car into zone 1 and out of zone 1 when all operations in zone 1 are done. rungs 1 2 3 4 are essentally providing necessary logics for belt to move . 1 PTAG.SYSTEM_STATUS / PULSE_OFF_TIME.DN Greater Than (A>B) Source A STEPS_COUNTERS.PRE 0 Source B 0 GRT / STEPS_COUNTERS.DN EN DN Timer On Delay Timer PULSE_ON_TIME Preset 2000 Accum 0 TON rungs 1 2 3 4 are essentally providing necessary logics for belt to move . 2 PULSE_ON_TIME.DN EN DN Timer On Delay Timer PULSE_OFF_TIME Preset 2000 Accum 0 TON 3 PULSE_ON_TIME.TT / STEPS_COUNTERS.DN BELT <Local:6:O.Data.29> 4 PULSE_OFF_TIME.DN Move Source 1 Dest BELT_MOVED 0 MOV 5 / PTAG.SYSTEM_STATUS RES STEPS_COUNTERS WHEN ZONE 1 OPERATION IS DONE A INDICATIONIS SEND TO ZONE 2 6 Equal Source A WHICH_STAGE 0 Source B 4 EQU PULSE_OFF_TIME.DN PTAG.ZONE1_STATUS WHEN ZONE 1 OPERATION IS DONE A INDICATIONIS SEND TO ZONE 2 (End)
  • 9.
    SEQ_OPERATIONS - LadderDiagram Page 1 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:36:06 PM Total number of rungs in routine: 4 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 this subroutie callsother sub routiens which carry out the required actions in zone 1 0 Jump To Subroutine Routine Name PRESOAK Input Par PTAG.MODE JSR this subroutie callsother sub routiens which carry out the required actions in zone 1 1 PRESOAK_OPERATION_DONE Jump To Subroutine Routine Name FOAM_APPLICATOR Input Par PTAG.MODE JSR 2 FOAM_OPERATION_DONE Jump To Subroutine Routine Name SCRUBBER Input Par PTAG.MODE JSR ONCE ZONE 1 OPERATIONS ARE COMPLETED system is ready to except new car in zone one and after it moves current car in zone 1 3 SCRUB_OPERATION_DONE Move Source 0 Dest BELT_MOVED 0 MOV Move Source 4 Dest WHICH_STAGE 0 MOV ONCE ZONE 1 OPERATIONS ARE COMPLETED system is ready to except new car in zone one and after it moves current car in zone 1 (End)
  • 10.
    PRESOAK - LadderDiagram Page 1 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:44:17 PM Total number of rungs in routine: 9 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 this routine carries out the presoak operation the rungs 1 and 2 set the required speed based upon the mode( number of cars waiting in the queue) 0 Equal Source A PTAG.MODE 0 Source B 1 EQU Move Source 1500 Dest M1_PRESOAK_T2.PRE 0 MOV Move Source 1500 Dest M1_PRESOAK_T1.PRE 0 MOV this routine carries out the presoak operation the rungs 1 and 2 set the required speed based upon the mode( number of cars waiting in the queue) 1 Equal Source A PTAG.MODE 0 Source B 2 EQU Move Source 1000 Dest M2_PRESOAK_T1.PRE 0 MOV Move Source 1000 Dest M2_PRESOAK_T2.PRE 0 MOV the rungs 2-7 controls the presoak oepration with help of couple of timers 2 M1_PRESOAK_T2.DN M2_PRESOAK_T2.DN CU DN Count Up Counter NO_OF_PRESOAK Preset 5 Accum 0 CTU the rungs 2-7 controls the presoak oepration with help of couple of timers 3 PTAG.SYSTEM_STATUS Equal Source A PTAG.MODE 0 Source B 1 EQU / M1_PRESOAK_T2.DN GATE_CLOSE_SENSOR <Local:5:I.Data.25> EN DN Timer On Delay Timer M1_PRESOAK_T1 Preset 0 Accum 0 TON
  • 11.
    PRESOAK - LadderDiagram Page 2 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:44:21 PM Total number of rungs in routine: 9 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 4 M1_PRESOAK_T1.DN EN DN Timer On Delay Timer M1_PRESOAK_T2 Preset 0 Accum 0 TON 5 PTAG.SYSTEM_STATUS Equal Source A PTAG.MODE 0 Source B 2 EQU / M2_PRESOAK_T2.DN GATE_CLOSE_SENSOR <Local:5:I.Data.25> EN DN Timer On Delay Timer M2_PRESOAK_T1 Preset 0 Accum 0 TON 6 M2_PRESOAK_T1.DN EN DN Timer On Delay Timer M2_PRESOAK_T2 Preset 0 Accum 0 TON 7 M1_PRESOAK_T1.DN / M1_PRESOAK_T2.DN M2_PRESOAK_T1.DN / M2_PRESOAK_T2.DN / NO_OF_PRESOAK.DN PRESOAK_RUNNING <Local:6:O.Data.27> 8 NO_OF_PRESOAK.DN PRESOAK_OPERATION_DONE (End)
  • 12.
    FOAM_APPLICATOR - LadderDiagram Page 1 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:44:51 PM Total number of rungs in routine: 5 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 THSI ROUTIE CARRY OUT THE FOAM APPLICAATION OERATION BASED ON THE MODE AND ONCE THE OERATION IS DONE ITS INDICATED FOR THE NEXT ZONE 0 PTAG.SYSTEM_STATUS / PULSE_OFF_TIME.DN / STEPS_COUNTERS.DN EN DN Timer On Delay Timer PULSE_ON_TIME Preset 2000 Accum 0 TON THSI ROUTIE CARRY OUT THE FOAM APPLICAATION OERATION BASED ON THE MODE AND ONCE THE OERATION IS DONE ITS INDICATED FOR THE NEXT ZONE 1 PTAG.SYSTEM_STATUS Equal Source A PTAG.MODE 0 Source B 1 EQU Move Source 8000 Dest M1_FOAM_DURATION.PRE 0 MOV PRESOAK_OPERATION_DONE EN DN Timer On Delay Timer M1_FOAM_DURATION Preset 0 Accum 0 TON 2 PTAG.SYSTEM_STATUS Equal Source A PTAG.MODE 0 Source B 2 EQU Move Source 5000 Dest M2_FOAM_DURATION.PRE 0 MOV PRESOAK_OPERATION_DONE EN DN Timer On Delay Timer M2_FOAM_DURATION Preset 0 Accum 0 TON 3 M1_FOAM_DURATION.TT M2_FOAM_DURATION.TT FOAM_APPLICATOR_RUNNING <Local:6:O.Data.18> 4 M1_FOAM_DURATION.DN M2_FOAM_DURATION.DN FOAM_OPERATION_DONE
  • 13.
    FOAM_APPLICATOR - LadderDiagram Page 2 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:44:54 PM Total number of rungs in routine: 5 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 (End)
  • 14.
    SCRUBBER - LadderDiagram Page 1 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:45:30 PM Total number of rungs in routine: 10 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 THIS ZONE CARRYS OUT THE SCRUBBING OPERATION AND ONCE THIS OPERATION IS DONE IT MARKS THE END OF ZONE ONE OPERATION AND WAIT AND MAKES THE WHICH SATE WHICH INDICATES THE END OF ZONE 1 0 M2_SCRUB_T2.DN M1_SCRUB_T2.DN CU DN Count Up Counter NO_OF_SCRUBS Preset 5 Accum 0 CTU THIS ZONE CARRYS OUT THE SCRUBBING OPERATION AND ONCE THIS OPERATION IS DONE IT MARKS THE END OF ZONE ONE OPERATION AND WAIT AND MAKES THE WHICH SATE WHICH INDICATES THE END OF ZONE 1 1 Equal Source A PTAG.MODE 0 Source B 1 EQU Move Source 2000 Dest M1_SCRUB_T1.PRE 0 MOV Move Source 2000 Dest M1_SCRUB_T2.PRE 0 MOV 2 Equal Source A PTAG.MODE 0 Source B 2 EQU Move Source 1000 Dest M2_SCRUB_T1.PRE 0 MOV Move Source 1000 Dest M2_SCRUB_T2.PRE 0 MOV 3 PTAG.SYSTEM_STATUS / NO_OF_SCRUBS.DN Equal Source A PTAG.MODE 0 Source B 1 EQU / M1_SCRUB_T2.DN FOAM_OPERATION_DONE EN DN Timer On Delay Timer M1_SCRUB_T1 Preset 0 Accum 0 TON 4 M1_SCRUB_T1.DN EN DN Timer On Delay Timer M1_SCRUB_T2 Preset 0 Accum 0 TON
  • 15.
    SCRUBBER - LadderDiagram Page 2 PLC_CARWASH_PROJECT:MainTask:MainProgram 12/12/2015 10:45:34 PM Total number of rungs in routine: 10 C:Userskxr3779DocumentsPLC_CARWASH_PROJECT.ACD RSLogix 5000 5 PTAG.SYSTEM_STATUS / NO_OF_SCRUBS.DN Equal Source A PTAG.MODE 0 Source B 2 EQU / M2_SCRUB_T2.DN FOAM_OPERATION_DONE EN DN Timer On Delay Timer M2_SCRUB_T1 Preset 0 Accum 0 TON 6 M2_SCRUB_T1.DN EN DN Timer On Delay Timer M2_SCRUB_T2 Preset 0 Accum 0 TON 7 M1_SCRUB_T1.TT M2_SCRUB_T1.TT / PTAG.SYSTEM_STATUS SCRUB_ACTION_1 <Local:6:O.Data.30> 8 M1_SCRUB_T2.TT / PTAG.SYSTEM_STATUS M2_SCRUB_T2.TT SCRUB_ACTION2 <Local:6:O.Data.31> 9 NO_OF_SCRUBS.DN SCRUB_OPERATION_DONE (End)
  • 16.
    MainRoutine - LadderDiagram Page 1 PCL_CAR_WASH_PROJECT_ZONE2:MainTask:MainProgram 12/12/2015 10:50:24 PM Total number of rungs in routine: 8 C:Userskxr3779DocumentsPCL_CAR_WASH_PROJECT_ZONE2.ACD RSLogix 5000 Koyya Shiva Karthik Reddy ZONE2 (Rinse , Wax Applicator, Dryer) this run recives system status and the status of zone one itself to start sone 2. 0 CTAG.SYSTEM_STATUS CTAG.ZONE1_STATUS / ZONE2_STATUS.0 ZONE2_IN_OPERATION.0 Koyya Shiva Karthik Reddy ZONE2 (Rinse , Wax Applicator, Dryer) this run recives system status and the status of zone one itself to start sone 2. as zone 2 starts sequence of opeartions are done. THE seq_operation is in structured text language. 1 ZONE2_IN_OPERATION.0 Jump To Subroutine Routine Name seq_operation JSR as zone 2 starts sequence of opeartions are done. THE seq_operation is in structured text language. once all operations of the zone 2 are done the exit gate is opened and car is moved out and and exit gate is then closed (indicated in rungs 2 3 4 ) 2 DRYING_OPERATION_DONE EXIT_GATE_OPEN <Local:6:O.Data.16> once all operations of the zone 2 are done the exit gate is opened and car is moved out and and exit gate is then closed (indicated in rungs 2 3 4 ) 3 GATE_OPENED <Local:5:I.Data.24> Jump To Subroutine Routine Name BELT_CONTROL JSR 4 / CTAG.SYSTEM_STATUS Equal Source A BELT_MOVED 0 Source B 1 EQU CLOSE_EXIT_GATE <Local:6:O.Data.17> as zone 2 c ar is movedout its sends a incicator to zone 1 that it is reay to except new car into zone 2. and also it dispalys the cars washed ( indicated in rungs 5-end) 5 GATE_CLOSED <Local:5:I.Data.20> ZONE2_STATUS.0 CU DN Count Up Counter NUMBER_OF_CARS_WASHED Preset 10000 Accum 0 CTU as zone 2 c ar is movedout its sends a incicator to zone 1 that it is reay to except new car into zone 2. and also it dispalys the cars washed ( indicated in rungs 5-end)
  • 17.
    MainRoutine - LadderDiagram Page 2 PCL_CAR_WASH_PROJECT_ZONE2:MainTask:MainProgram 12/12/2015 10:50:28 PM Total number of rungs in routine: 8 C:Userskxr3779DocumentsPCL_CAR_WASH_PROJECT_ZONE2.ACD RSLogix 5000 6 To BCD Source NUMBER_OF_CARS_WASHED.ACC 0 Dest DISPLAY 0 TOD Masked Move Source DISPLAY 0 Mask MASK 2#0000_0000_0000_0000_0000_0000_0000_0000 Dest CARS_WASHED <Local:6:O.Data> 0 MVM 7 / CTAG.SYSTEM_STATUS Masked Move Source 0 Mask MASK 2#0000_0000_0000_0000_0000_0000_0000_0000 Dest CARS_WASHED <Local:6:O.Data> 0 MVM (End)
  • 18.
    BELT_CONTROL - LadderDiagram Page 1 PCL_CAR_WASH_PROJECT_ZONE2:MainTask:MainProgram 12/12/2015 10:50:49 PM Total number of rungs in routine: 5 C:Userskxr3779DocumentsPCL_CAR_WASH_PROJECT_ZONE2.ACD RSLogix 5000 his routie controls the moment of car outside the car wash by controlling the belt movement 0 PULSE_OFF_TIME.DN CU DN Count Up Counter STEPS_COUNTERS Preset 0 Accum 1 CTU his routie controls the moment of car outside the car wash by controlling the belt movement 1 / PULSE_OFF_TIME.DN EN DN Timer On Delay Timer PULSE_ON_TIME Preset 1000 Accum 0 TON 2 PULSE_ON_TIME.DN EN DN Timer On Delay Timer PULSE_OFF_TIME Preset 1000 Accum 0 TON 3 ZONE2_IN_OPERATION.0 PULSE_ON_TIME.TT / STEPS_COUNTERS.DN BELT <Local:6:O.Data.29> 4 PULSE_OFF_TIME.DN Move Source 1 Dest BELT_MOVED 0 MOV (End)
  • 19.
    SEQ_OPERATIONS - LadderDiagram Page 1 PCL_CAR_WASH_PROJECT_ZONE2:MainTask:MainProgram 12/12/2015 10:51:30 PM Total number of rungs in routine: 3 C:Userskxr3779DocumentsPCL_CAR_WASH_PROJECT_ZONE2.ACD RSLogix 5000 this subroutine call all other sub routies to perform the required sequense of operations 0 Jump To Subroutine Routine Name RINSE JSR this subroutine call all other sub routies to perform the required sequense of operations 1 RINSE_DONE Jump To Subroutine Routine Name WAX_APPLICATOR JSR 2 WAXING_OPERATION_DONE Jump To Subroutine Routine Name DRYER Input Par PTAG.MODE JSR (End)
  • 20.
    RINSE - LadderDiagram Page 1 PCL_CAR_WASH_PROJECT_ZONE2:MainTask:MainProgram 12/12/2015 10:55:13 PM Total number of rungs in routine: 10 C:Userskxr3779DocumentsPCL_CAR_WASH_PROJECT_ZONE2.ACD RSLogix 5000 THIS routine controls the rinsing operation and as soon as the operation is done it indicats that its done rinsing 0 M2_RINSE_T2.DN M1_RINSE_T2.DN CU DN Count Up Counter NO_OF_RINSE_CYCLE Preset 5 Accum 0 CTU THIS routine controls the rinsing operation and as soon as the operation is done it indicats that its done rinsing 1 Equal Source A CTAG.MODE 0 Source B 1 EQU Move Source 5000 Dest M1_RINSE_T1.PRE 0 MOV Move Source 5000 Dest M1_RINSE_T2.PRE 0 MOV 2 Equal Source A CTAG.MODE 0 Source B 2 EQU Move Source 3000 Dest M2_RINSE_T1.PRE 0 MOV Move Source 3000 Dest M2_RINSE_T2.PRE 0 MOV 3 / NO_OF_RINSE_CYCLE.DN Equal Source A CTAG.MODE 0 Source B 1 EQU / M1_RINSE_T2.DN EN DN Timer On Delay Timer M1_RINSE_T1 Preset 0 Accum 0 TON 4 M1_RINSE_T1.DN EN DN Timer On Delay Timer M1_RINSE_T2 Preset 0 Accum 0 TON 5 / NO_OF_RINSE_CYCLE.DN Equal Source A CTAG.MODE 0 Source B 2 EQU / M2_RINSE_T2.DN EN DN Timer On Delay Timer M2_RINSE_T1 Preset 0 Accum 0 TON
  • 21.
    RINSE - LadderDiagram Page 2 PCL_CAR_WASH_PROJECT_ZONE2:MainTask:MainProgram 12/12/2015 10:55:17 PM Total number of rungs in routine: 10 C:Userskxr3779DocumentsPCL_CAR_WASH_PROJECT_ZONE2.ACD RSLogix 5000 6 M2_RINSE_T1.DN EN DN Timer On Delay Timer M2_RINSE_T2 Preset 0 Accum 0 TON 7 ZONE2_IN_OPERATION.0 M1_RINSE_T1.TT M2_RINSE_T1.TT RINSE_ACTION1 <Local:6:O.Data.30> 8 ZONE2_IN_OPERATION.0 M1_RINSE_T2.TT M2_RINSE_T2.TT RINSE_ACTION2 <Local:6:O.Data.31> 9 NO_OF_RINSE_CYCLE.DN RINSE_DONE (End)
  • 22.
    WAX_APPLICATOR - LadderDiagram Page 1 PCL_CAR_WASH_PROJECT_ZONE2:MainTask:MainProgram 12/12/2015 10:55:48 PM Total number of rungs in routine: 9 C:Userskxr3779DocumentsPCL_CAR_WASH_PROJECT_ZONE2.ACD RSLogix 5000 this routie controls the waxing operation and once its done waxing it indicates that its done waxing. 0 Equal Source A CTAG.MODE 0 Source B 1 EQU Move Source 1500 Dest M1_WAX_T1.PRE 0 MOV Move Source 1500 Dest M1_WAX_T2.PRE 0 MOV this routie controls the waxing operation and once its done waxing it indicates that its done waxing. 1 Equal Source A CTAG.MODE 0 Source B 2 EQU Move Source 1000 Dest M2_WAX_T1.PRE 0 MOV Move Source 1000 Dest M2_WAX_T2.PRE 0 MOV 2 M1_WAX_T2.DN M2_WAX_T2.DN CU DN Count Up Counter WAX_APPLICATOR_COUNTER Preset 5 Accum 0 CTU 3 Equal Source A CTAG.MODE 0 Source B 1 EQU / M1_WAX_T2.DN RINSE_DONE EN DN Timer On Delay Timer M1_WAX_T1 Preset 0 Accum 0 TON 4 M1_WAX_T1.DN EN DN Timer On Delay Timer M1_WAX_T2 Preset 0 Accum 0 TON 5 Equal Source A CTAG.MODE 0 Source B 2 EQU / M2_WAX_T2.DN RINSE_DONE EN DN Timer On Delay Timer M2_WAX_T1 Preset 0 Accum 0 TON 6 M2_WAX_T1.DN EN DN Timer On Delay Timer M2_WAX_T2 Preset 0 Accum 0 TON 7 ZONE2_IN_OPERATION.0 M1_WAX_T1.DN / M1_WAX_T2.DN M2_WAX_T1.DN / M2_WAX_T2.DN WAX_APPLICATOR_RUNNIMG <Local:6:O.Data.27>
  • 23.
    WAX_APPLICATOR - LadderDiagram Page 2 PCL_CAR_WASH_PROJECT_ZONE2:MainTask:MainProgram 12/12/2015 10:55:53 PM Total number of rungs in routine: 9 C:Userskxr3779DocumentsPCL_CAR_WASH_PROJECT_ZONE2.ACD RSLogix 5000 8 WAX_APPLICATOR_COUNTER.DN WAXING_OPERATION_DONE (End)
  • 24.
    DRYER - LadderDiagram Page 1 PCL_CAR_WASH_PROJECT_ZONE2:MainTask:MainProgram 12/12/2015 10:57:03 PM Total number of rungs in routine: 4 C:Userskxr3779DocumentsPCL_CAR_WASH_PROJECT_ZONE2.ACD RSLogix 5000 THIS routine controls the drying operation and the duration based on mode and indicated once the drying operation is done 0 Equal Source A CTAG.MODE 0 Source B 1 EQU Move Source 10000 Dest M1_DRYER_DURATION.PRE 0 MOV / M1_DRYER_DURATION.DN WAXING_OPERATION_DONE EN DN Timer On Delay Timer M1_DRYER_DURATION Preset 0 Accum 0 TON THIS routine controls the drying operation and the duration based on mode and indicated once the drying operation is done 1 Equal Source A CTAG.MODE 0 Source B 2 EQU Move Source 5000 Dest M2_DRYER_DURATION.PRE 0 MOV / M2_FOAM_DURATION.DN WAXING_OPERATION_DONE EN DN Timer On Delay Timer M2_DRYER_DURATION Preset 0 Accum 0 TON 2 ZONE2_IN_OPERATION.0 M1_DRYER_DURATION.TT M2_DRYER_DURATION.TT DRYER_RUNNING <Local:6:O.Data.18> 3 M1_DRYER_DURATION.DN M2_DRYER_DURATION.DN DRYING_OPERATION_DONE (End)