TI - 3222: Otomasi Sistem Produksi
Pr ogr a m m a ble Logic Con t r olle r
Labor at or ium
Labor at or ium Sist emSist em Pr oduksiPr oduksi
w w w .lspit b.or g
w w w .lspit b.or g
©
©20042004
D e pa r t e m e n Te k n ik I n du st r i FTI - I TB
Hasil Pembelajaran
•
Um um
Mahasiw a m am pu unt uk m elakukan pr oses per ancangan
sist em ot om asi, sist em m esin NC, ser t a m erancang dan
m engim plem ent asikan sist em k ont r ol logika.
•
Khusus
TI-3222: Otomasi Sistem Produksi - 7
3
PURPOSE OF Programmable
Logic Controllers (PLCs)
•
I nit ially designed t o r eplace r elay logic boar ds
Sequence device act uat ion
Coor dinat e act ivit ies
•
Accept s input fr om a ser ies of sw it ches
•
Sends out put t o dev ices or r elay s
D e pa r t e m e n Te k n ik I n du st r i FTI - I TB
PURPOSE OF Programmable
Logic Controllers (PLCs)
•
I nit ially designed t o r eplace r elay logic boar ds
Sequence device act uat ion
Coor dinat e act ivit ies
•
Accept s input fr om a ser ies of sw it ches
TI-3222: Otomasi Sistem Produksi - 7
5
FUNCTI ONS OF CONTROLLERS
•
1) on- off cont r ol,
•
2) sequent ial cont r ol,
•
3) feedback cont r ol, and
•
4) m ot ion cont r ol.
D e pa r t e m e n Te k n ik I n du st r i FTI - I TB
CONTROL DEVI CES
1) m echanical cont r ol - cam , governor, et c.,
2) pneum at ic cont r ol - com pr essed air , valves,
et c.
3) elect r om echanical cont r ol - sw it ches, r elays,
a t im er , count ers, et c,
4) elect ronics cont rol - sim ilar t o
elect rom echanical cont rol, except uses
elect ronic sw it ches.
TI-3222: Otomasi Sistem Produksi - 7
7
PROGRAMMABLE LOGI C
CONTROLLER
Invented in 1968 as a substitute for hardwired relay panels.
" A digit ally oper at ing elect r onic appar at us which uses a pr ogr am m able m em or y for t he int er nal st or age of inst r uct ions by im plem ent ing specific funct ions such as logic sequencing, t im ing, count ing, and ar it hm et ic t o cont r ol, t hr ough digit al or analog input / out put m odules, various t ypes of m achines or pr ocesses. The digit al com put er w hich is used t o per for m t he funct ions of a pr ogr am m able cont r oller is consider ed t o be w it hin t his scope. Excluded ar e dr um and ot her sim ilar m echanical sequencing cont r oller s."
National Electrical Manufacturing Association (NEMA)
D e pa r t e m e n Te k n ik I n du st r i FTI - I TB
VENDORS
•
Rockw ell
•
GE/ Fanuc
•
Schnieder
•
MODI COM - GOULD
•
ALLEN- BRADLEY
•
Honeyw ell
•
SQUARE- D
TI-3222: Otomasi Sistem Produksi - 7
9
PLC
CPU
System
User Ladder Diagram
Working memory registers
Input
Flag
Output
Input Module
Output Module
D e pa r t e m e n Te k n ik I n du st r i FTI - I TB
TI-3222: Otomasi Sistem Produksi - 7
1 1
What devices does a PLC interact with?
•
I NPUT RELAYS- ( cont act s) These ar e connect ed t o t he out side t heir count ing speed. Som e m anufact ur er s also include high-speed count er s t hat ar e har dw ar e based. We can t hink of t hese as physically exist ing. Most t im es t hese count er s can count up, dow n or up and dow n.D e pa r t e m e n Te k n ik I n du st r i FTI - I TB
TI-3222: Otomasi Sistem Produksi - 7
1 3
SWI TCHES
DPST SPDT
Non-locking Locking
Normally Open Normally Closed
Multiple Throw P1
P2
Multiple Pole
Break-before-make Make-before-break
D e pa r t e m e n Te k n ik I n du st r i FTI - I TB
TERMS
Th r ow - n u m be r of st a t e s
Pole - n u m be r of con n e ct in g m ov in g p a r t s ( n u m be r of in div idu a l cir cu it s) .
DPST
A serial switch box (A-B box) has two 25 pin serial ports to switch from.
Input Output
A B
Knob
TI-3222: Otomasi Sistem Produksi - 7
1 5
TYPES OF SWI TCHES
1. Basic sw it ch, oper at ed by a m echanical level, 2. Push- but t on sw it ch,
3. Slide sw it ch, 4. Thum bw heel sw it ch, 5. Lim it sw it ch,
6. Pr ox im it y sw it ch, and 7. Phot oelect r ic sw it ch.
RATING: voltage, current
D e pa r t e m e n Te k n ik I n du st r i FTI - I TB
RELAYS
A switch whose operation is activated by an electromagnet is called a "relay"
contact
coil
input
TI-3222: Otomasi Sistem Produksi - 7
1 7
COUNTER
Digit al count er s out put in t he for m of a r elay cont act w hen a pr eassigned count value is r eached.
Register
Accumulator
contact input
reset
output
Input Reset Output
Count 0 1 2 3 4 5 0 1
5
D e pa r t e m e n Te k n ik I n du st r i FTI - I TB
TI MER
A t im er consist s of an int er nal clock, a count value r egist er , and an accum ulat or. I t is used for or som e t im ing pur pose.
Clock
Accumulator
contact reset
output Register
Contact Clock Reset Output
TI-3222: Otomasi Sistem Produksi - 7
1 9
AN EXAMPLE OF RELAY LOGI C
L1
TI-3222: Otomasi Sistem Produksi - 7
2 1
EEPROM ( Elect r onically Er asable Pr ogr am m able ROM) ,4. Pow er supply AC power
5. Peripher al Hand held pr ogr am m er ( loader ) , CRT pr ogram m er,
Oper at or console, Pr int er,
Sim ulat or, EPROM loader , Casset t e loader , Gr aphics pr ocessor , and
TI-3222: Otomasi Sistem Produksi - 7
2 3
LADDER DI AGRAM
A ladder diagr am ( also called cont act sy m bology) is a m eans of gr aphically r epr esent ing t he logic r equir ed in a r elay logic syst em .
A R1
PB1 PB2
R1
R1
start emergency stop
Rail
Rung
D e pa r t e m e n Te k n ik I n du st r i FTI - I TB
TI-3222: Otomasi Sistem Produksi - 7
2 5
PLC WI RI NG DI AGRAM
01 02 20 20
20 11
01 02 03
11 12
A PLC
Input Output
External switches
Stored program
D e pa r t e m e n Te k n ik I n du st r i FTI - I TB
SCAN
begin
Input Output
Resolve logic Idle
A PLC r esolv es t he logic of a ladder diagr am ( pr ogr am ) r ung by r ung, fr om t he t op t o t he bot t om . Usually , all t he out put s ar e updat ed based on t he st at us of t he int er nal r egist er s. Then t he input st at es ar e check ed and t he cor r esponding input r egist er s ar e updat ed. Only aft er t he I / Os hav e been r esolv ed, is t he pr ogr am t hen ex ecut ed. This pr ocess is r un in a endless cy cle. The t im e it t akes t o finish one cy cle is called t he scan t im e.
TI-3222: Otomasi Sistem Produksi - 7
2 7
PLC I NSTRUCTI ONS
1) Relay,
2) Tim er and count er ,
3) Pr ogr am cont r ol,
4) Ar it hm et ic,
5) Dat a m anipulat ion,
6) Dat a t r ansfer , and
7) Ot her s, such as sequencer s.
D e pa r t e m e n Te k n ik I n du st r i FTI - I TB
LOGI C STATES
ON : TRUE, cont act closure, ener gize, et c.
OFF: FALSE, cont act open , de- ener gize, et c.
(In the notes we use the symbol "~" to represent negation. AND and OR are logic operators. )
TI-3222: Otomasi Sistem Produksi - 7
2 9
AND and OR LOGI C
PB1 PB2 R1
R2
R1 = PB1.AND.PB2
R2 = PB2.AND.~PB4 PB3 PB4
PB1 R1
PB2
R1 = PB1 .OR. PB2
AND
OR
D e pa r t e m e n Te k n ik I n du st r i FTI - I TB
COMBI NED AND & OR
R1 = PB1 .OR. (PB2 .AND. PB3)
PB1 R1
TI-3222: Otomasi Sistem Produksi - 7
3 1
Relay diagram symbols
D e pa r t e m e n Te k n ik I n du st r i FTI - I TB
TI-3222: Otomasi Sistem Produksi - 7
3 3
RELAY
A Relay consists of two parts, the coil and the contact(s).
Cont act s:
TI MERS AND COUNTERS
Tim er s:
PR value in 0.1 second
TI-3222: Otomasi Sistem Produksi - 7
3 5
SEQUENCER
TI-3222: Otomasi Sistem Produksi - 7
3 7
Programming a PLC
D e pa r t e m e n Te k n ik I n du st r i FTI - I TB
TI-3222: Otomasi Sistem Produksi - 7
3 9
Logic for Ladder Solution
D e pa r t e m e n Te k n ik I n du st r i FTI - I TB
TI-3222: Otomasi Sistem Produksi - 7
4 1
PROGRAMMI NG EXAMPLE 1
TI-3222: Otomasi Sistem Produksi - 7
