MFG 333 - Six Station PLC Programming (1)
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12MFG 333 – MANUFACTURING AUTOMATION
3Programmable Logic Control Programming
Objective:
The objective of this lab is to program a Programmable Logic Controller (PLC) for
one of the six assembly line stations. In doing so, you will further learn about PLC
programming and how it can be used for sequencing in a manufacturing setting. When you
finish the lab, submit all work on Learning Suite via your lab report.
Equipment & Materials:
Modular Production System Trainer System MPS1400 Series
PC with Windows OS and PLC Micrologix programming software installed
One of the three available six assembly line stations (1701, 1704, or 1705)
o
Check the white board next to your computer for your station
Station packet
Station PLC template code
Machined cups
Machined lids
Background:
The modern PLC might be thought of as a “blue-collar computer”. It takes the place of
the hard-wired relay panel used for the last hundred years to control machines and
processes that need timing and sequencing.
PLCs are typically programmed using ladder
diagrams.
A ladder diagram is a schematic of the actual wiring used to connect the components of
a relay panel. PLCs take the place of relay panels and usually are installed and
programmed by technicians trained in the wiring of relay panels. PLC creators opted to
continue the use of ladder diagrams for PLC programming because it would be easy for the
technicians to understand. Ladder logic programming is a versatile way to express
machine-control logic, but different from what most of us are used to in computer
programming languages.
Procedure:
1.
Use the following link to find your stations PLC code template, packet, and example
video. Link:
https://byu.box.com/s/yh41p6xxbwbcnrh692w3ou1p1e8t2b1j
If you are prompted to login to box, your login credentials are the same as
your BYU net ID and password.
2.
Download both the packet and PLC code template for your station and save it to one
of your group member’s J-drive.
3.
View the video in order to have a better understanding of what your station is
supposed to be doing.
4.
Next, download your template program onto your PLC station. To do this, start by
opening up “RSLogix 500”
5.
Click on “File”, “Open…”, and locate your downloaded PLC code template.
°
6.
Once your PLC code is open, your program should be in “OFFLINE” mode and you
can start programming.
7.
Before downloading and testing your PLC code, ensure your PLC is set to
“REMOTE” mode.
8.
Pull the drawer out for your station and locate the PLC display.
9.
Using the arrow pad, move down to “Mode Switch” and press “OK”. You will be led to
the following screen:
10.Using the arrow pad, move up to “Remote” and press “OK”.
11.
When you are ready to test your program, download the program to the PLC.
12.In order to do this, select “Comms”, “System Comms...”, and select the “AB_ETHIP-
1, Ethernet” driver.
13.Once selected, the following PLC list will appear:
°
*Note that only stations 1, 4, and 5 are currently connected because those are the PLC’s we will be
coding. The other stations are not connected only because they are not on.
14.From the PLC list, select your stations PLC (the final digit of the “Address” indicates
the station). For example, the screenshot below indicates you are selecting the PLC
for station 1.
15.After selecting your stations correct PLC (indicated by blue highlight), select
“Download”, “OK”, “Yes”, and “Yes”.
16.Because the PLC is on remote mode, you can use the top left drop down menu to
toggle between offline, run, etc. All code changes, however, will be done in offline
mode.
17.
IMPORTANT:
When saving your program, make sure you are in “Offline” mode. If
not set to this mode, your program will not save.
18.From here, use the station packet given to you to finish the PLC code necessary to
have the station run properly. This packet contains all inputs/outputs related to your
station, a process flow diagram describing how the station should run, and a hard
copy of all the code written in your PLC code template.
19.With this given information and the video provided, understand what key piece of
your code is missing and use sequential logic to program it out.
Report:
Discuss the challenges and advantages of PLC programming and the specific ones you
encountered while doing this lab. In your report, include screenshots of the PLC program
and descriptions of what each rung does.
°
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