PLC for Automatic Cutting Machine

See Animation : Cutting Machine


Cutting Machine : 

Detail Cutting Machine :

Notes :
LS = Limit Switch.
LS 1 = Limit Switch for Cutter Reverse.
LS 2 = Limit Switch for Cutter Forward.
LS 3 = Limit Switch for Clamp1 (Fixed) Forward (Clamp).
LS 4 = Limit Switch for Clamp1 (Fixed) Reverse (UnClamp).
LS 5 = Limit Switch for Clamp2 (Movable) Forward (Clamp).
LS 6 = Limit Switch for Clamp2 (Movable) Reverse (UnClamp).
LS 7 = Limit Switch for Clamp2 (Movable) Forward.
LS 8 = Limit Switch for Clamp2 (Movable) Reverse.

See : LS or Limit Switch

Number Of Inputs and Output PLC applied :
1. Number Of Inputs PLC is 11 Input :
--- 1 Unit Input for Push Button Start.
--- 1 Unit Input for Push Button Emg / Emergency.
--- 1 Unit Input for Selector Switch Electric Motor ON.
--- 8 Unit Input for Limit Switch (LS).
--- Total Number Of Inputs PLC is Minimum 11 Input Unit.

2. Number Of Output PLC is 9 Output :
--- 1 Unit Output for Contactor. It's Functions to electrical Motor Cutter ( ON / OFF Motor ) .
--- 2 Unit Output for Solenoid Cylinder Cutter : Forward - Reverse.
--- 2 Unit Output for Solenoid Cylinder Clamp1 : Clamp - UnClamp .
--- 2 Unit Output for Solenoid Cylinder Clamp2 : Clamp - UnClamp.
--- 2 Unit Output for Solenoid Cylinder Clamp2 : Forward - Reverse.
--- Total Number Of Outputs PLC is Minimum 9 Output Unit.

See : Solenoid

Sequence PLC Programming for Cutting Machines :

Step 1 :
a. If Push Button Emg = OFF Then All System OFF.
b. If LS 1 = ON And LS 4 = ON And LS 6 = ON And LS 8 = ON Then All Limit Switch Origin = ON.
c. If Push Button Emg = ON And Selector Switch Motor = ( OFF to ON ) And All Limit Switch Origin = ON Then Contactor Motor = ON.

Step 2 :
a. If Push Button Start = ON And Contactor Motor = ON And All Limit Switch Origin = ON Then Starts Automatic Cutting Process.
--- Download Animation : Cutting Machine
b. If have been three times ( Data Setting = 3 (Can be Changed) ) Then Stops Automatic Cutting Process And ALL Return Origin.
c. If Push Button Emg = Pulse ON Then ALL Return Origin. 
Source: http://program-plc.blogspot.com/2009/08/plc-for-automatic-cutting-machines.html

PLC Control for Automatic Welding Machine

Simulation : Automatic Welding Machine

Remarks :
1. Movement1 : Cylinder Clamp Left AND Right to Middle
2. Movement2 : Cylinder Ejector Down
3. Movement3 : Cylinder Clamp Left AND Right to Forward
4. Movement4 : Cylinder Nozzle to Middle
5. Movement5 : Cylinder Nozzle to Forward AND Welding Torch=ON
6. Movement6 : Cylinder Nozzle to Middle
7. Movement7 : Cylinder Nozzle to Reverse
8. Movement8 : Cylinder Clamp Left AND Right to Middle
9. Movement9 : Cylinder Clamp Left AND Right to Reverse
10. Movement10 : Cylinder Ejector Up

The results of welding product

Detail of Automatic Welding Machine

Legend for Detail of Automatic Welding Machine:
1. Raw Material for Welding
2a/2b. Push Button Start (Normally Open Contact)
2a. Start-1 (PB1)
2b. Start-2 (PB2)
NOTE: Push Button Start-1(PB1) And Push Button Start-2(PB2) Connected in Series
3a/3b. Safety Sensor
3a. Safety Sensor Receiver
3b. Safety Sensor Transmitter
NOTE: If NO OBJECT Then Safety Sensor=ON Else Safety Sensor=OFF
4. Cylinder Clamp Left
5. Cylinder Clamp Right
6. Limit Switch (LS) Clamp Left Reverse
7. Limit Switch (LS) Clamp Left Middle
8. Limit Switch (LS) Clamp Left Forward
9. Limit Switch (LS) Clamp Right Reverse
10. Limit Switch (LS) Clamp Right Middle
11. Limit Switch (LS) Clamp Right Forward
12. Cylinder Ejector
13. Cylinder Nozzle (for welding nozzle)
14. Limit Switch (LS) Ejector Up
15. Limit Switch (LS) Ejector Down
16. Limit Switch (LS) Nozzle Reverse
17. Limit Switch (LS) Nozzle Middle
18. Limit Switch (LS) Nozzle Forward
19. Welding Machine, such as GMAW(Gas Metal Arc. Welding)
20. Panel Box
21. Welding Nozzle / Welding Gun / Welding Torch

Example GMAW Welding: use MIG Welding
Circuit diagram of MIG Welding to PLC Output with contactor
Contactor coil to PLC Output and Contactor contact (NO) to Torch Button of MIG Welding

PLC Input and Output Devices :
1. PLC Input :
<-> 1 Input for Emergency Stop Button
<-> 1 Input for Push Button Start
<-> 1 Input for Safety Sensor
<-> 1 Input for Limit Switch Clamp Left Reverse
<-> 1 Input for Limit Switch Clamp Left Middle
<-> 1 Input for Limit Switch Clamp Left Forward
<-> 1 Input for Limit Switch Clamp Right Reverse
<-> 1 Input for Limit Switch Clamp Right Middle
<-> 1 Input for Limit Switch Clamp Right Forward
<-> 1 Input for Limit Switch Ejector Up
<-> 1 Input for Limit Switch Ejector Down
<-> 1 Input for Limit Switch Nozzle Reverse
<-> 1 Input for Limit Switch Nozzle Middle
<-> 1 Input for Limit Switch Nozzle Forward
--> Total PLC Input, minimum of 14 Input.

2. PLC Output :
<-> 1 Output for Contactor to Torch Button of MIG Welding
<-> 1 Output for Solenoid to Clamp Left Reverse
<-> 1 Output for Solenoid to Clamp Left Forward
<-> 1 Output for Solenoid to Clamp Right Reverse
<-> 1 Output for Solenoid to Clamp Right Forward
<-> 1 Output for Solenoid to Ejector Up
<-> 1 Output for Solenoid to Ejector Down
<-> 1 Output for Solenoid to Nozzle Reverse
<-> 1 Output for Solenoid to Nozzle Forward
--> Total PLC output, minimum of 9 Output.

NOTE: All Solenoid using Double Solenoid,3 Position ( 4/3 ways or 5/3 ways ),Closed Center

Sequence PLC Programming for Automatic Welding Machine :

1. INPUT CONDITION :
a. Waiting Start (Output Controller1) = ON, If:
a.1. Emergency Stop = ON
b.2. Waiting Start = OFF AND Safety Sensor = OFF

b. All Origin = ON, If:
b.1. Emergency Stop = OFF
b.2. Safety Sensor = ON
b.3. Limit Switch Clamp Left Reverse = ON
b.4. Limit Switch Clamp Right Reverse = ON
b.5. Limit Switch Ejector Up = ON
b.6. Limit Switch Nozzle Reverse = ON

c. Start = ON, If:
c.1. Emergency Stop = OFF
c.2. Safety Sensor = ON
c.3. Push Button Start = ON

2. TRIGGER AND SENSOR CONDITION :
a. Waiting Start / Output Controller1: All Origin AND Start
b. Movement1 / Output Controller2: Cylinder Clamp Left AND Right to Middle
c. Movement2 / Output Controller3: Cylinder Ejector Down
d. Movement3 / Output Controller4: Cylinder Clamp Left AND Right to Forward
e. Movement4 / Output Controller5: Cylinder Nozzle to Middle
f. Movement5 / Output Controller6: Cylinder Nozzle to Forward ANDWelding Torch=ON
g. Movement6 / Output Controller7: Cylinder Nozzle to Middle
h. Movement7 / Output Controller8: Cylinder Nozzle to Reverse
i. Movement8 / Output Controller9: Cylinder Clamp Left AND Right to Middle
j. Movement9 / Output Controller10: Cylinder Clamp Left AND Right to Reverse
k. Movement10 / Output Controller11: Cylinder Ejector Up

3. OUTPUT CONDITION :
a. Use Internal Relay for the output:
a.1. If Output Controller (2 or 9) = ON AND LS Clamp Middle (Left/Right) = ON Then LS Clamp Middle (Left/Right) = HOLD ON
a.2 If Output Controller (3 or 10 or 1) = ON Then LS Clamp Middle (Left/Right) = HOLD OFF
b. Output Controller 2 AND HOLD ON LS Middle for Solenoid Clamp Left Forward
c. Output Controller 2 AND HOLD ON LS Middle for Solenoid Clamp Right Forward
d. Output Controller 3 for Solenoid Ejector Down
e. Output Controller 4 for Solenoid Clamp Left Forward
f. Output Controller 4 for Solenoid Clamp Right Forward
g. Output Controller 5 for Solenoid Nozzle Forward
h. Output Controller 6 for Solenoid Nozzle Forward
i. Output Controller 6 for Contactor Welding Torch=ON
j. Output Controller 7 for Solenoid Nozzle Reverse
k. Output Controller 8 for Solenoid Nozzle Reverse
l. Output Controller 9 AND HOLD ON LS Middle for Solenoid Clamp Left Reverse
m. Output Controller 9 AND HOLD ON LS Middle for Solenoid Clamp Right Reverse
n. Output Controller 10 for Solenoid Clamp Left Reverse
o. Output Controller 10 for Solenoid Clamp Right Reverse
p. Output Controller 11 for Solenoid Ejector Up

4. CONTROLLER :
Using 11 Output Controller :
total movement = 10 movement
Waiting Start = 1
Total Output Controller = 10 + 1 = 11

Can You make Program Ladder PLC ?

Please using Standard Sequence Programming 

source: http://program-plc.blogspot.com/2011/10/plc-control-for-automatic-welding.html 

Password using PLC

Simulation Password 



Detail for Password Using PLC


Information on Numbers for Detail the Password Using PLC : 
1. KeyPad with 10 Numeric and 1 Enter (Numeric KeyPad)
2. PLC (Programmable Logic Controller)
3. Red Light for Wrong Password
4. Green Light for Correct Password 


Wiring from the Numeric KeyPad to PLC


Information on Wiring from the Numeric KeyPad to PLC : 
1. Input 0 PLC for Numeric 0 from KeyPad
2. Input 1 PLC for Numeric 1 from KeyPad
3. Input 2 PLC for Numeric 2 from KeyPad
4. Input 3 PLC for Numeric 3 from KeyPad
5. Input 4 PLC for Numeric 4 from KeyPad
6. Input 5 PLC for Numeric 5 from KeyPad
7. Input 6 PLC for Numeric 6 from KeyPad
8. Input 7 PLC for Numeric 7 from KeyPad
9. Input 8 PLC for Numeric 8 from KeyPad
10. Input 9 PLC for Numeric 9 from KeyPad
11. Input 10 PLC for ENTER from KeyPad 

Number Of Inputs and Output PLC applied :
1. Number Of Inputs PLC is 11 Input :
--- 11 Unit Input from Numeric KeyPad 
--- Total Number Of Inputs PLC is Minimum 11 Input Unit. 

2. Number Of Output PLC is 2 Output :
--- 1 Unit Output to Red Light for Wrong Password 
--- 1 Unit Output to Green Light for Correct Password 
--- Total Number Of Outputs PLC is Minimum 2 Output Unit. 


Sequence PLC Programming for Password PLC : 

1. Correct Password
a. If typing "5500" from KeyPad AND "ENTER" from KeyPad then Green Light = ON (Correct Password) 

2. Wrong Password
a. If NOT typing "5500" from KeyPad AND "ENTER" from KeyPad then Red Light = ON (Wrong Password) 

3. Password Data
a. Password data using PLC memory (With Value 5500) and can be modified 

4. Green Light = OFF OR Red Light = OFF
a. If Enter Released AND Typing again then Green Light = OFF OR Red Light = OFF
(source : http://program-plc.blogspot.com)

Programming servo motor

1. Positioning Module QD75M1 parameters:

2. Servo Amplifier (MR-J2S-B) and Servo Motor (HC-KFS73) Parameter :

3. Start Operation
For Start Operation X20 = ON

4. Positioning Data
4.a. Positioning Data No.1

4.b. Positioning Data No.2

5. Positioning Start No.1 and No.2
For positioning Start X21 = ON


(source : http://program-plc.blogspot.com)

Servo diagram

Here's an example Servo Wiring Diagram for Q-series PLC from Mitsubishi, Positioning module, servo amplifier and motor servo. 

Servo Wiring Diagram

PLC for application of servo motor

Component is needed for the servo wiring diagram is: 
1. Q62P PLC Power Supply ( MELSEC-Q Mitsubishi ).
2. CPU unit Q02CPU ( MELSEC-Q Mitsubishi ).
3. Positioning Module QD75M1 ( MELSEC-Q Mitsubishi ).
4. Servo amplifier MR-J2S-B ( Mitsubishi ).
5. MR Buss Cable J2HBUS1M ( Mitsubishi ).
6. End Terminal MR-A-TM ( Mitsubishi ).
7. Limit Switch to Zero Position .
8. Encoder cable JCCBL05M MR-H ( Mitsubishi ).
9. MR-PWCNK2 connector ( Mitsubishi ).
10. Servo motor HC-KFS73 ( Mitsubishi ).

Application for Servo

Information for Applications servo motor: 
1. Push Button Switch with Light for Start Operation / Zero Position.
2. Push Button Switch with Light for Positioning Start.
4. Limit Switch to Zero Position.
3. Ball Screw with gear lead (µm/rev) = 10mm.
4. Servo Motor.
5. Servo Amplifier.
6. PLC MELSEC-Q.
7. Positioning Module QD75M1.


Number Of Inputs and Output PLC applied :
1. Number Of Inputs PLC is 2 Input :
--- 1 Unit Input for Push Button Switch for Start Operation. 
--- 1 Unit Input for Push Button Switch for Positioning Start. 
--- Total Number Of Inputs PLC is Minimum 2 Input Unit.


2. Number Of Output PLC is 2 Output :
--- 1 Unit Output for Light Push Button Switch in Start Operation / Zero Position. 
--- 1 Unit Output for Light Push Button Switch in Positioning Start. 
--- Total Number Of Outputs PLC is Minimum 2 Output Unit.


Sequence for Application of Servo Motor with PLC MELSEC-Q ( Mitsubishi ): 

Step 1 : Start Operation / Zero Position 
a. If Push Button Start OPR = ON Then JOG = ON ( Manual Operation To LS Zero ) . 
b. If LS Zero = ON Then Start OPR = ON in Positioning Module QD75M1. 
c. Waiting Servo to Positioning Operation Complete. 


Step 2 : Positoning Start 
a. If Push Button Start = ON Then Positoning Start No.1 = RUN ( To 20mm ) And Waiting Positioning Complete. 
b. If Positioning Complete = ON Then Positoning Start No.2 = RUN ( To 40mm ) And Waiting Positioning Complete.
(source : http://program-plc.blogspot.com)