Control system

CONTROL SYSTEMANDAUTOMATION
Mohammed MunthearAlqaderi, munthear@gmail.com

Automation System
Field Level
Group Control Level
Cell Level
Process Control Level
Production
Management level
Company
Management Level

Components
Machines
Processes
Production
System Size
System Capability

TYPE OFINDUSTRIAL PROCESS
BATCH PRODUCTION,
CONTIUOUS PRODUCTION,
DISCRETE ITEM PRODUCTION,
LABORATORY SYSTEMS

BATCH PRODUCTION
Sequence of Operations, Complete cycle, Discontinuous control.
Repeatability.
Change of Specification.
Set –Up Time, ( change –over time).
Operation Time / Wasted Time.
NC ( Numerically Controlled ).

Batch Processes example
Tank 2
Polymer
Tank1
Alkali
Tank3
Reactionvessel
Product silo
Filter

CONTIUOUS PRODUCTION
The Production is maintained for long periods of time without interruption.
The variable can be changed without halting the process.
The problem is change –over from one specification to other.

CONTIUOUS PRODUCTION example
Thick steel input
(slow speed)
Sheet steel Output (high speed)
Roller System
Controlled pressure

DISCRETE ITEM PRODUCTION
Individual item undergoes various operations before being produced in a final form.
Several components may be combined or assembled.

DISCRETE ITEM PRODUCTIONexample
CNC
DrillingMachine
Formingmachine
Robot
Input Conveyor
Output Conveyor

الأنظمة المخبرية
تجارب أو اختبارات معقدة أو اختبارات روتينية
اختبارات الجودة وفرز الأصناف

Basic system categories
• Stochastic Deterministic
Static Dynamic
Distributed Lumped
Non-linear Linear
Continuous Discrete

Robust Control
Can the system tolerate noise?
Adaptive Control
Controller changes over time (adapts)
MIMO Control
Multiple inputs and/or outputs
Stochastic Control
Controller minimizes variance
Optimal Control
Controller minimizes a cost function of error and control energy
Nonlinear systems
Neuro-fuzzy control
Challenging to derive analytic results
Advanced Control Topics

CONTROL STRATEGY
OPEN-LOOP Control.
FEEDFORWARD Control.
CLOSD-LOOP ( feedback ) Control.
Direct Digital Control ( DDC ).

Open –Loop Control
Requirements
Action
Outcome
Disturbances
Control
Plan
Plant
System

Feed Forward Control
Requirements
Action
Outcome
Control
Plan
Plant
System
Disturbances

Feedback Control
Requirements
Action
Outcome
Control
Plan
Plant
System
Disturbances
+
error

Direct Digital Control (DDC)
A
A
A
Digital
Computer
Process
Setpoints
Measured
variable
HumanandorComputerSupervision
Process
Inputs
Process
Output

Activities being carried out
Data acquisition;
Data analysis;
Sequence or/and loop control;
Supervisory control;
Data storage;
Human-Computer Interface ( HCI );

Objectivesof Computerized Control
Efficiency of Operation;
Ease of operation;
Safety;
Improved products;
Reduction in waste;
Reduced environmental impact;
Reduction in direct labour;

مسألة تتابعي Sequential problem
المسألة معقدة وكبيرة
المسألة بسيطة وصغيرة
خطوات غير واضحة
SCRIPTS
FLOW CHART
ترتيب في
خطوات المعالجة
مخطط الحالة
STATE DIAGRAM
SFC/GRAFSET
PETRI شبكات
معادلات
BLOCK LOGIC
زمن التطوير قصير
الأداء مهم
توقيت في قدح الحالة
لا يوجد انتظار
بإشارة الحالة
معالجة مفردة
معالجة متعددة

مكونات نظام التحكم المؤتمت :
1 ( المنظومة الفيزيائية :
هي الآلة المراد أتمتة أعمالها بما في ذلك خطوط نقل الحركة وآلات التجميع وآلات التعبئة
والتغليف وآلات البلاستيك و الصناعات الغذائية ...
2 ( المشغلات :
هي العناصر والأدوات التي تعمل على تفعيل وظائف الآلة ، مثل المحركات والمضخات و
الصمامات و المكابس و أنظمة التسخين .
3 ( الحساسات :
هي العناصر والأجهزة التي تزود جملة التحكم والأتمتة بالمعلومات اللازمة وتضم حساسات
المستوى وحساسات الحرارة وحساسات السرعة والضغط والتدفق .
4 ( جملة التحكم والأتمتة :
هو الجهاز الذي يعمل على معالجة معطيات الدخل ويقوم بتوليد تتابع الخرج وفق برنامج محدد
مخزن بداخله مسبقا .
5 ( وسائل التخاطب والمراقبة:
عبارة عن وسائل تؤمن اظهار متغيرات النظام المراد مراقبته وتسمح بتدخل خارجي من الانسان
لتعديل متحولات أو تنفيذ عملية معينة .

الجملـة اًلفيزيائيـة )ًالآلـة(
الحساسات
جهاز اًلتحكم
واجهـة اًلتخاطب بًين اًلإنسان وً اًلآلـة
المشغلات

Sensor Systems
Sensor
temperature sensors
flow sensors
level sensors
pressure sensors
composition analyzers
Transmitter

Better Actuators
Provide more Muscle
Better Sensors
Provide better Vision
Better Control
Provides more finesse by combining sensors and
actuators in more intelligent ways

TerminologyProgrammable Controller
PCProgrammable Controller (UK origin),
PBSProgrammable Binary System (Swedish origin),
PLCProgrammable Logic Controller (US origin),
SBCSingle Board Computer (US origin),
RTURemote Terminal Unit ( US origin),
DDCDirect Digital Control (Britain Origin),

PLC
PC
Environment
The PLC was specifically designed for harsh conditions with electrical noise, magnetic fields, vibration, extreme temperatures or humidity.
Common PCs are not designed for harsh environments.Industrial PCs are available but cost more.
Ease of Use
By design PLCs are friendlier to technicians since they are in ladder logic and have easy connections.
Operating systems like Windows are common.Connecting I/O to the PC is not always as easy.
Flexibility
PLCs in rack form are easy to exchange and add parts.They are designed for modularity and expansion.
Typical PCs are limited by the number of cards they can accommodate and are not easily expandable.
Speed
PLCs execute a single program in sequential order.The have better ability to handle events in real time.
PCs, by design, are meant to handle simultaneous tasks.They have difficulty handling real time events.
Reliability
A PLC never crashes over long periods of time.("Never" may not be the right word but its close enough to be true.)
A PC locking up and crashing is frequent.
Programming languages
Languages are typically fixed to ladder logic, function block or structured text.
A PC is very flexible and powerful in what to use for programming.
Data management
Memory is limited in its ability to store a lot of data.
This is where the PC excels because of it's hard drive.Any long term data storage, history and trending is best done on a PC.
Cost
Just too hard to compare pricing with so many variables like I/O counts, hardware needed, programming software, etc.

PLC or DCS: What is the difference?

Programmable Logic Controller
PLC
محمد منذر القادري

PLC developments
 1968Programmable controller concept developed.
 1969Hardware CPU controller, with logic instruction, 1k of memory and 128 I/O points.
 1974Use of several processors within a PLC –timers and counters, arithmetic operations, 12k of memory and 1024 I/O points.
 1976Remote input/output systems introduced.
 1977Microprocessor-based PLC introduced.
 1980Intelligent I/O modules developed,
Enhanced communications facilities,
Enhanced software features,
Use of personal microcomputer as programming aids.
 1983Low-cost small PLC introduced.
 1985on Networking of all levels of PLC, computer and Machine under standard specification.
 Distributed, hierarchical control of industrial plants.

Advantage of PLC
Flexibility.
Numerous contacts.
Low in price.
Simulated operation advance.
Fast execution speed.
Use ladder chart in planning circuits.
High reliability.
Easy maintenance.
Simplify the purchasing process of the elements in the control system.
Easily translated to file data .
Highly security.

Disadvantage of PLC
New technique.
Unsuitable to be used in the place of fixed function.
Environmental impacts.

(Special & communication module)
A/Dmodule
D/Amodule
T/Cmodule
RTDmodule
AnalogTimer
PIDmodule
Positionmodule
Interruptmodule
HSCmodule
G4F-AD3A(8Ch)
G4F-AD2A(4Ch)
G4F-DA3V(8Ch)
G4F-DA3I(8Ch)
G4F-DA2V(4Ch)
G4F-DA2I(4Ch)
G4F-DA1A(2Ch)
G4F-TC2A(4Ch)
G4F-RD2A(4Ch)
G4F-AT3A(8pts)
G4F-PIDA(8loops)
G4F-HSCA(1ch)
G4F-POPA(1Axis)
G4F-INTA
Ethernetmodule
Fieldbusmodule
Serialmodule
Device Netmodule
(10Mbps)
(1Mbps) )
(RS232C/RS422)
Moduler PLC

طرق التوصل
اشهر طرق التوصيل هي :
1 - mesh )) نسيجي ((
2 - star )) نجمي ((
3 - tree )) شجري ((
4 - bus )) ناقل ((
5 - ring )) حلقي ((

Physical Topology
Star Topology
Mesh Topology Bus Topology
Ring Topology
Tree Topology

1 - mesh (( يجيسن )) ا نيب طابترلاا ةرثكب زيمتي لأ يف زاهج لك عم رشابم طابترا دجوي هزهج ةكبشلا
الميزة الكبيرة للنسيجي هي وضوح الاخطاء.
2 - star )) نجمي (( سمي نجمي نسبه الى شكل التوصيل فيه هنا كل الكوابل تمرر من الحواسيب الى نقطه
مركزيه والنقطة المركزيه تسمى الـ hub وظيفة الـ hub اعادة ارسال الرسائل الى كل الحواسيب او الى
حاسب معين ونستطيع استخدام اكثر من نوع في هذه الشبكه . كما انه من السهل تعديل وإضافة حاسب جديد
من دون تعطيل الشبكه وأيضا تعطل حاسب في الشبكه لا يعطلها لكن عند تعطل الـ hub تتعطل الشبكه
كاملة. وكما ان هذه الطريقه تكلف الكثير من الكوابل .
3 - tree )) شجري (( سمي بذلك نسبه الى كثرة التفرعات فيه هنا يمكننا ربط شبكات من النوع نجميه
بإضافة hub اخر بهذا يتم تشكيل شبكة الـ tree 4 - bus )) ناقل (( سمي بذلك لأنه عبارة عن خط مستقيم يستخدم في الشبكات الصغيرة والبسيطة و يكون
تصميم الشبكه هذه بتوصيل الكمبيوترات في صف على طول سلك واحد يسمى الـ )) backbone (( .لا
توجد بالسلك اي تقويه للإشارات المرسلة من حاسب الى اخر . عند ارسال اي رسالة من اي حاسب على
السلك كل الحواسيب الاخرى تصلها الاشارة، لكن واحد فقط يقبلها . حاسب واحد فقط يسمح له بالإرسال في
نفس الوقت نستنتج هنا ان عدد الأجهزه فيها يؤثر على سرعتها من اهم الادوات المستخدمه في هذه الشبكه
الـ terminators يستخدم لامتصاص الاشارات ومنعها من الانعكاس مرة اخرى .
5 - ring )) حلقي ((
سميت بذلك نسبه الى شكلها ، لأننا نربط الأجهزه بشكل حلقي هنا في هذه الشبكه كل حاسب متصل مع
الحاسب الذي يليه في شكل حلقه في اتجاه واحد بحيث يكون اخر حاسب متصل مع اول حاسب وكل حاسب
ينقل ويرسل المعلومات التي استقبلها من الحاسب السابق الى الحاسب الذي يليه شبكات الـ ring تستخدم
الـ token وهو عبارة عن رسالة قصيرة تمر داخل الشبكة لتنقل المعلومات من حاسب الى اخر يمكننا
تصميم شبكات من نوع مختلط ،

السوية 4
DeviceNet , UnitTelway
نموذج المراقبة والتحكم التراتبي
أعمال مكتبية إ
دارة الإنتاج م
راقبة الجودة ت
صميم بمساندة الحاسوب
نحو شبكة المؤسسة و / أو شبكة عمومية
TOP, ..
MAP
Factor ,...…
MAP
تخطيط السيرورة ت
صنيع بمساندة الحاسوب
تنسيق وإشراف ص
يانة
السوية 3
التصنيع المتكامل بواسطة الحاسوب
CIM
(=Computer Integrated Manufacturing)
حساس م
نظم م
شغل
السوية 1
تحكم
BitBus , FIP ProFiBus
ModBus , LAC ,…
Mini-MAP
شبكة ميدانية
تحكم رقمي ت
حكم بروبوت
بالآلة
صناعية
قيادة ومتابعة
SCAD
شبكات الاتصالات في مجال الرقابة و التحكم

SIMATIC NET and SINAUT Station control systemsSCADA ServerApplication ServerOperatorStationTrainingStationEngineer. StationOperatorStationOperatorStationPrinterServerFront EndProcessorControlCenterSCADA ServerApplication ServerOperatorStationTrainingStationEngineer. StationOperatorStationOperatorStationPrinterServerFront EndProcessorBack-UpControlCenterRTURTURTURTURTURTURTUStation Control SystemESDESDStationControl SystemWANWANWide ide Area rea NNetworketworkDedicated linesDialinglinesPear to pearradio linkDedicatedradio linkFOTSFOTSFiberoptic•Analog•ISDN•GSM•SMSMonitoring and controlWith WinCCTelecontrolwith SIMATIC S7SINAUTTIM Module...... plus ....... within a completely integrated system

SIMATIC NET and SINAUT Station control systems
SCADA Server Application Server
Operator
Station
Training
Station
Engineer.
Station
Operator
Station
Operator
Station
Printer
Server
Front End
Processor
Control
Center
SCADA Server Application Server
Operator
Station
Training
Station
Engineer.
Station
Operator
Station
Operator
Station
Printer
Server
Front End
Processor
Back-Up
Control
Center
RTU RTU RTU RTU RTU RTU RTU
Station Control
System
ESD ESD
Station
Control System
WAN
Wide Area Network
Dedicated
lines
Dialing
lines
Pear to pear
Dedicated radio link
radio link
FOTS
FOTS
Fiber
optic
•Analog
•ISDN
•GSM
•SMS
Monitoring and control
With WinCC
Telecontrol
with SIMATIC S7
SINAUT
TIM Module
...... plus .......
within a completely integrated system

النواقل الحقلية هي شبكة نقل رقمية تسلسلية تزود خدمة
الاتصال بين العناصر الحقلية ) المنتشرة ( مثل
الحساسات والمشغلات و المتحكمات
النواقل الحقلية

Network and protocol standards

Field-Bus System
Profibus DP/FMS/PA
Ethernet (10Mbps)
Fast Ethernet (100 Mbps)
Interbus-S
DeviceNet
CANopen/CANbus
Modbus
AS-Interface
Foundation Fieldbus H1
Genius Lan (GEF anuc)
Serial Standard Interface RS-232/422/485
AB remote I/O
LonWorks
ABB proprietary
Honeywell DE
Seriplex
Yokogawa propirtary

ان استخدام الطبقات السبع للـ OSI على مستوى العنصر ) عنصر الشبكة ( بطيئ جدا
ومعقد جدا عند ارسال الرسائل القصيرة او المتكررة لذا كان من الضروري في هذه
التطبيقات ان تعدل طبقة التطبيقات للوصول مباشرة الى طبقة التطبيقات .

Network Devices and the OSI Model

شبكة رقمية تسلسلية تستخدم كناقل حقلي في تطبيقات النظم الصناعية المؤتمتة يمكن ان
تربط بين جميع انواع العناصر الحقلية والمنتشرة على المستوي الحقلي
شبكة CAN

PWR
FSM
INPUT
OUTPUT
OUTPUT
PMU
opt Max 3km
Cable
. .
. .
. .
. .
. .
. .
. .
Active Coupler
(optic)
EOC
(opt/elec.
Converter)
Max.64 Stations
(Max.2 Slot
Allowed)
1Mbps Twisted pair
Max. 750m long
Max.5.25km
Repeater(Max. 6) Repeater
Remote I/O Remote I/O
Stand-alone
Remote
DC In (16P)
Stand-alone
Remote Relay
Out(16P)
PWR
CPU
F- net
INPUT
OUTPUT
PWR
CPU
F- net
INPUT
OUTPUT
PWR
CPU
F- net
INPUT
OUTPUT
PWR
CPU
F- net
INPUT
OUTPUT
PWR
CPU
F- net
INPUT
OUTPUT
PWR
FSM
INPUT
OUTPUT
OUTPUT
Terminator
Network System (Fnet-Fieldbus)

Communication methods1) Simplex
This is a communication type that the data is transmitted with a fixed direction. It is not allowed to move data in reverse direction. 2) Half-duplex
It is available to move data in both directions. However, data transference in a direction should be
done after another direction transference is completed because two- way transmissions share acommon communication cable.
3) Full-duplex
Data is transmitted in two-way directions with two communication cables.

Input Unit Output Unit
Memory Unit
Program Input
Device
Power Supply
C P U
Block Diagram of PLC

ROM
Arithmeti
c logic
unit
Register
Control
unit
Central
control unit
Power
supply
Battery
Analyti
c unit
RAM
Periphe
ral
Control
unit
Input
unit
Interf
ace
contro
l unit
Output
unit
AC
power
Output
module
Input
module
Tape unit
Disk drive
Program
panel
printer
Switch
component
sensor
Motor,electromagnetic
valve
Light,heater
compute
r
Block Diagram

I
n
t
e
r
n
a
l
c
i
r
c
u
i
t
24V+
(24V-)
X2
X1
X0
   C
Example for
input
connection
EA model should
be add the power
source externally
No this power
source in EA
model
Open collestor
NPN transistor
Power supply of
sensor(served as
input in EA model)
DC-24V Input circuit
24VDC
24VDC
Input Circuit

CR4 CR5 CR6 CR7
Internal circuit
Relay on output circuit
+24V
C4 Y4 Y5 Y6 Y7
R PL
Indicat
or
light
Bulb
ligh
t
Electr
om-agneti
c
valve
Rela
y
Main
power
CR
4
CR
5
CR
6
CR
7
Output Circuit

filter stabilizer
Battery
(backup
power
sysyem)
Power
conditioner
T2
T1
+ Rectifier
-
+
-
+
0
-
G
+
0
-
G
+
-
0
-
+
-
0
-
Sensing the
scale of voltage
+5Vdc
0
-5Vdc
TO CPU
L1
L2
G
T1
T2
G
Power supply

Power specification
Item
Specification
Incoming Power
Voltage
100〜240VAC ，-15%〜+10%
Frequency
50〜60Hz ，-5%〜+5%
Rated power
30VA（max.）
Inrush current
20A @ 264VAC
Voltage drop and interruption
20ms（min.）
Fuse rating
1.25A ，250VAC
Power outputs
5VDC(for CPU)
5V ，±5%，1A（max.）
24VDC(for output)
24V ，±15%，400mA（max.）
24VDC(for input and Sensor)
24V ，±15%，400mA（max.）
Isolation
Transformer/optical，1500VAC/1min.

Relay Ladder
Diagram
(U.S.A.)
Function Block
Diagram
(Germany)
Sequential
Function Chart
(France)
Instruction List
(U.S.A./Germany)
C
Pascal
Ada
LD
FBD
SFC
IL
ST
Graphical
Textual
Global Standard programming language for PLC
IEC1131-3
◎International Standard IEC1131-3 adapted
◎IEC1131-3 based language supporting LD, IL, SFC Programming Languages

The ISaGRAF Software Development Kit (SDK) allows you to develop simple or complex applications using industry standard IEC-61131 languages. ISaGRAF supports the following 6 traditional control programming languages (all 5 specified by the IEC-61131-3 standard, plus Flow Chart):
•Sequential Function Chart (SFC)
•Function Block Diagram (FBD)
•Flow Chart (FC)
•Ladder Diagram (LD)
•Structured Text (ST)
•Instruction List

X10
X100
M100
Y0
M505
X3
X0 X1
Y126
Y1
Y0
Input processing (Reading the
status of all external input terminals)
Output processing (Outputting the resul-ting
signals to external output terminals)
First
step
Last step
PLC sequentially executes
the stored program and gets
new output results (has not
sent to external terminals
yet)
Cyclic execution
Sequentially executes

M
MC
TH-RY
NFB
R S T
OFF ON
TH-RY
MC/a
MC-a
Running indicator light
MC-b
RL
WL
MC
Stop indicator light
example1

【PLC ladder diagram】
X0 X1 X2
Y0
Y0
Y0
Y0
Y1
Y2
example1

【The connection diagram of PLC output/input】
PLC
ON OFF TH-RY
C X0 X1 X2
C Y0 Y1 Y2
R T
MC WL RL
example1

M
R S T
OFF ON 1
ON 2
MC1
MC2
MC2/b
MC1/b
TH-RY
MC1/a
MC2/a
MC1/b MC2/b
MC1 MC2
WL
MC1
YL
RL
MC2
BZ
example2

Y0
X0 X2 X3 Y1
Y0
Y1
X1 X2 X3 Y0
Y1
Y2
Y0
Y3
Y1
Y5
X3
Y4
Y0 Y1
PLC ladder diagram example2

BZ
MC2
RL
YL
WL
MC1
Y5
Y4
Y3
Y2
Y1
Y0
X3
X2
X1
X0
C
C
PLC
T
R
TH-RY
OFF
ON2
ON1
PLC output／input wiring chart
example2

MC1
TH-RY
NFB
R S T
M
V
U W
X
Y
Z
MCY
MC
OFF ON
MC
TR
BZ
MC
WL
MCY
RL
TH-RY
MC/a
MC/a MC /b
TR
MC/a
MC/b
example3

EN
1S
T200 R0
X0 X1 X2
Y0
Y0 Y2
T200
Y0
Y0
X2
Y0
Y1
Y2
Y3
Y4
Y5
example3

Y5 BZ
Y4
Y3
Y2
Y1
Y0
X2
X1
X0
C
C
PLC
T
R
OFF
ON
TH-RY1 RL
WL
MC
MCY
MC
exampe3

X5 X6 Y3
Y3
X5 X6 Y3
Y3
Conventional Ladder PLC Ladder Diagram
Diagram
ladder

Y4
X11
X14
Y0 M6
X16
X10
X12
M1 X20
X0 X1
X7 X10
X2
X9
X3 X4 X5 X6
/
Y4
Y5
/
Y2
Y0
Element Node Parallel block Serial block
Origin line
Network 1
Network 2
Network 3
Branch
Sample Ladder Diagram Ladder

Branch
Branch line Merge
line Ladder

X0 X1
ORG X
AND X1
X1
X0 X2 ORG X0
OR X1
AND X2
X2
X0 X1 X3
ORG X0
AND X1
OR X2
AND X3
Ladder

Y0 ORGSHORT
OUT Y0
X0 X1
X3
X2 X4
Serial Block
Must use ANDLD instruction
ANDLD instruction is not necessary
ORG X0
AND X1
LD X2
OR X3
ANDLD
AND X4
Ladder

X0 X1 X2 Y0
X4
X3
X5
Block 1 Block 2
Block 3
ORG X0
ANDNOT X1
LD NOT X2
AND X3
LD x4
ANDNOT X5
ORLD
ANDLD
OUT Y0
Ladder

X0 X1 X4 Y0
X6
X5
X2 X3 X7
Block 1 Block 2
ladder

STP S0
M1924
STP S20
X1
X0 Y0
STP S23
Y1
STP S21
Y2
STP S22
Y3
S0
X2 X3
X5 X4 X6
X7
X8
Y4
SFC

Step flow chart
S0
S20
X2
Y0
X3
X1
M1942
X0
S0
Y1
S21
S22
X7
X5
X11 Y3
X4
X6
Y2
X8
SFC

S0
S20
S21
S32
S23
S30
S31
Parallel
forward
divergence
Parallel
forward
confluence
S0
S20
S21
S22
S23
Repeat
Jump
(ｃ) Burst divergence, confluence (ｄ) Jump, repeat
SFC

S0
S20
S21
S22
S23
S0
S20
S21
S22
S23
S24
S25
Selective
divergence
Selective
confluence
(b) selective divergence,
(a) Single flow confluence
SFC

FLOWCHART BASED DESIGN
•Describing process control using flowcharts
•Conversion of flowcharts to ladder logic

Dry material Liquid
Clean
water
Product outlet
Empty limit
switch
X2
No-fluid
limit switch
Empty limit
switch
Valve 1
Gate 1
AD1:R3840
Weighing
Mixer
Mixer motor
Valve 2 Valve 3
Electromagneti
c switch
Overload switch
Valve 4
X1
Y7:
Y5:
Y6:
Y9:
X3
Y10:
X4
Y8:
Mixer

Description:
．Inputpoint:Startbutton,X6．Weightinput: AD1,R3840
Washingbutton,X7
Warningclearbutton,X5
．Warningindicator:Drymaterialempty,Y1
Liquiddeficiency,Y2
Mixingunitempty,Y3
Motoroverload,Y4
．Outputpoint:DrymaterialfeedingvalveY5
DrymaterialfeedinggateY6
LiquidfeedinggateY7
StartmotorelectromagneticvalveY8
CleanwaterfeedvalveY9
ProductdeliveryvalveY10
Mixer

S0 SET Y1
SET Y2
SET Y3
SET Y4
X1
X2
X3
X4
S20
Sa:R3840
Sb:R0
17CMP M0
M1
Y5
S21
M0 M1
Y6
T0 500
S22
Y7
T1 800
Feeding
to mixer
Add fluid
to mixer
S23
Y8
T2 4500
Mix
X4 Y4
S25
Y10
DR10
Product
delivery
X3
S25 15D
+1
S24
Y9 Feed clear
water to
wash mixer
T3
T3 500
T4 Y10
T4 1500
Drainage
X5
SET Y1
SET Y2
SET Y3
SET Y4
M1924
X6
Y1
Y2
Y3
Y4
Y3
Y4
X7
T1
T0
T2
X3
Cycle
accumulation
Motor
overload
T4
Feeding
weighing
Weighing
input
Warning
indication
Warning
clear
Mixer

【Step flow chart】
STP S23 Mixing
Y8
EN T2 4500
X4 Y4
STP S24
Y9
EN T3 500
T3
Y10
EN T4 1500
T4
TO S25
T2
FROM S23
FROM S24
T4
STP S25
Y10
+1 DR10
S25
X3
X3
15D
TO S0
STPEND
Motor
overload
Clear water
feed-in to
wash mixer
Drainage
Product
delivery
Cycle
accumulation
Net 7
Net 8
Net 9
Net 10
Net 11
Mixer

G2 Y2 R2
G2 Y2 R2
R1 Y1 G1
G1 Y1 R1
Road # 2
Road # 1
Illustration of traffic light】
Traffic

X1 X2
M0
M0
M0
EN
0
MC 0
X3 X0
M3
M1
X4 X0
M4
M2
X0 M1
EN
1S
T200 16
T200
EN
1S
T201 2
T203
EN
1S
T202 2
T201
M3
EN
0.1S
T50 5
T201 T51
T50
EN
0.1S
T51 5
M4
T200 T202
M3
X0
EN
1S
T203 6
M1 M2
Start the stop control
Main loop
Manual loop control
←T─20─0
T201
T202
T50
T51
T203
M3
M4
M1
¡ö¢w
Time for the first set green
light
←──Time for the blinking green
light
←──Time for the yellow light on
←── Speed of blinking green light
←──Time for the second set
green light
M1 and M2 are the switches over
control of the first and second Use PLC in traffic light control
Traffic

Green light 1
T203 T202
M4
T201 T50
X0 T200
X0 M3
M1
M1 T201 T202
M1
X0 T203
X0 M4
T201 T50
M1
M1 T201 T202
X0 T200
X0 M3
T202
M1
M1 T202
EN
1
MCE 0
M2
Y0
Y1
Y2
Y3
Y3
Y3
Yellow light 1
Red light 1
Green light 2
Yellow light 2
Red light 2
Use PLC in traffic light control
Traffic

YL2
GL2
RL1
Y5
Y4
Y3
Y2
Y1
Y0
X2
X1
X0
C
C
PLC
T
R
PB2
PB1
YL1
GL1
RL2
PB4
PB3
X4
X3
CS
The first set
The second set
PLC output／input wiring chart
Traffic

PLC
C0 Y0 Y1 Y2 Y3 C1 Y4 Y5
C X0 X1 X2 X12 X13 X14 X15
8 4 2 1 8 4 2 1 8 4 2 1 8 4 2 1
103 102 101 100
SW0 SW1 SW2
PL1 PL2
R T
Display

X1
EN RST R0
EN
15P
(+1)
R0 OVF
X0
X2
EN
16P
(-1)
R0 UDF
X0
EN
20->BCD
S=R0
D=R1
ERR
EN
79-7SGOL
S=R1
OT=Y4
N=2
ON
EN
17CMP
Sa:R0
Sb:20
a=b
a>b
a<b
Y0
Y1
X1
EN RST R0
EN
15P
(+1)
R0 OVF
X0
X2
EN
16P
(-1)
R0 UDF
X0
EN
20->BCD
S=R0
D=R1
ERR
EN
79-7SGOL
S=R1
OT=Y4
N=2
ON
EN
17CMP
Sa:R0
Sb:20
a=b
a>b
a<b
Y0
Y1
Display

PS1 PS2
PLC
RL GL
R T
C Y0 Y1 Y2 Y3 Y 4 Y5 Y6 Y7 Y8 Y9 Y10 Y 11
C X0 X1 X2
8 4 2 1 8 4 2 1 8 4 2 1 8 4 2 1
+24V
COM
SW0
Display

Pulse input
t
Step angle t
output
Driving
circuit of
step motor
Step
motor
Stepper Motor

EN
PAU
MD:1
Fr:R0
PC:0
CK:Y0
DR:Y1
HO:
U/D
X0
X1
X2
EN
13 (*)
Sa:R0
Sb:6
D:R1
EN
14 (/)
Sa:R1
Sb:20
D:R3
EN
20→BCD
S:R3
D:R5
EN
79 7SGDL
S:R5
OT:Y4
N:2
81.PLS0
Use PLC in speed control of step motor
Stepper Motor

SW1
PLC
C
Y0 Y1 Y4~Y11
X0 X1 X2
C
SW0 SW2
Driving circuit
COM
24V
To 7-segment LED
CKDIR
Step motor
(refer ro related wiring
in previous)
SW0: pulse output enables
SW1: Pause pulse output enables
SW2: Positive and reverse rotation control (ON: Positive, OFF reverse)
CK: Pulse input end of step motor.
DIR: Directional control end of step motor.
Stepper Motor

Control system

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