Q1.
Operating a charge and discharge process
Charge and discharge of a reservoir is a common process in industry as well as a need for
mixing two or more substances. By using automated valves this process can be
completely automated. Let's say that fluid used in the example is water, and that a
reservoir has to be filled up and emptied four times. When you push T1 on the operating
panel, valve V1 opens and a reservoir starts filling up with water. At the same time, motor
M of the mixer starts working. When the reservoir fills up, water level goes up and reaches
the level set by a sensor S1. V1 valve closes and motor of the mixer stops. Valve V2 opens
after 2 secs, and a reservoir starts emptying. When water level falls below the level set by
a sensor S2, valve V2 closes. By repeating the same cycle four times, lamp that indicates
end of a cycle is activated. Pressing T1 key will start a new cycle. Develop ladder and
simulate using PLC.
Q2 - Control of a Mixing Process
The mixing process is to function as follows: Assume that the tank is empty at the starting
time. When the start button (Start) is operated, magnetic valve MV1 opens so that water
flows into the tank
When the level in the tank reaches level transmitter LT2, the water supply is shut off and
the motor for the conveyor belt starts at the same time that the agitator (stir) starts. When
the level comes up to transmitter LT3, the motor will stop and the magnetic valve MV2
on the outlet is opened (the agitator will continue to run). When the level comes below
LT2, the agitator is also stopped. The sequence can now be started anew by activating the
start button.
Q3- Mixing Process :
Mixing Process Figure 1 shows a sketch of the mixing process. The facility consists ofthe
following: tank with pipe, three fluid pumps, one mixer, one heater, three level indicators
calibrated for various fluid levels, and a control panel with signal lights and spring‐loaded
push buttons. During operation, two products will be filled into one tank. The mixture
will then be warmed up during mixing. When a desired temperature is reached, the tank
is emptied.
Description of the sequence:
• In the initiation step, the Ready light will be lit. The sequence will start when the Start
button is pressed. Then Pump1 starts, the Ready light turns off, and the Run light lights.
• When Level1 gives a high signal, Pump1 stops and Pump2 starts. At the same time, the
Mixer starts.
• When Level2 becomes TRUE, Pump2 stops and the Heater is turned on.
• When the desired temperature is reached, Temp >= 50°C, the heater is turned off.
• Five seconds after that, the Mixer stops and Pump3 starts.
• When the tank is Empty (becomes logically low), the whole sequence is repeated
automatically 50 times. Then the Run lamp turns off, and the Ready lamp lights again.
Q4 - Sequential Process
A sequential control process is required for processes that demand that certain
operations be performed in a specifi c order. Figure 6-53 illustrates part of a bottle fi lling
process. In the fi lling and capping operations, the tasks are (1) fi ll bottle and (2) press
on cap. These tasks must be performed in the proper order. Obviously we could not fi ll
the bottle after the cap is pressed on. This process, therefore, requires sequential control.
Combination control process.
Combination controls require that certain operations be performed without regard to the
order in which they are performed. Figure 6-54 illustrates another part of the same bottle
fi lling process. Here, the tasks are (1) place label 1 on bottle and (2) place label 2 on
bottle. The order in which the tasks are performed does not really matter. In fact,
however, many industrial processes that are not inherently sequential in nature are
performed in a sequential manner for the most effi cient order of operations
Sequential process flow diagram
The converting of a simple sequential process can be examined with reference to the
process fl ow diagram illustrated in Figure 6-56 . The sequential task is as follows: 1. Start
button is pressed. 2. Table motor is started. 3. Package moves to the position of the limit
switch and automatically stops. Other auxiliary features include: • A stop button that will
stop the table, for any reason, before the package reaches the limit switch position • A red
pilot light to indicate the table is stopped • A green pilot light to indicate the table is
running
Q5 - Filling operation
Figure 6-67 shows the sketch of a continuous filling operation. This process requires that
boxes moving on a conveyor be automatically positioned and filled.
The sequence of operation for the continuous filling operation is as follows:
• Start the conveyor when the start button is momentarily pressed.
• Stop the conveyor when the stop button is momentarily pressed.
• Energize the run status light when the process is operating.
• Energize the standby status light when the process is stopped.
• Stop the conveyor when the right edge of the box is first sensed by the photosensor.
• With the box in position and the conveyor stopped, open the solenoid valve and allow
the box to fi ll. Filling should stop when the level sensor goes true.
• Energize the full light when the box is full.
The full light should remain energized until the box is moved clear of the photosensor.
Q6. Sequential light system
Write a program to simulate the operation of a sequential taillight system. The light
system consists of three separate lights on each side of the car. Each set of lights will be
activated separately, by either the left or right turn signal switch. There is to be a 1 s delay
between the activation of each light, and a 1-s period when all the lights are off. Ensure
that when both switches are on, the system will not operate. Use the least number of
timers possible.
The sequence of operation should be as follows:
• The switch is operated.
• Light 1 is illuminated.
• Light 2 is illuminated 1 s later.
• Light 3 is illuminated 1 s later.
• Light 3 is illuminated for 1 s.
• All lights are off for 1 s.
• The system repeats while the switch is on.
Q7- Counting sequence:
Figure 8-7 illustrates the counting sequence of an upcounter and a down-counter. The
value indicated by the counter is termed the accumulated value. The counter will
increment or decrement, depending on the type of counter, until the accumulated value
of the counter is equal to or greater than the preset value, at which time an output will be
produced. A counter reset is always provided to cause the counter accumulated value to
be reset to a predetermined value.
Luggage movement
Write a PLC program to allow the operator to run the conveyor line for luggage
transportation by pushing a START push button. The START push button is a normally
open momentary switch, and the STOP push button is normally closed and wired high.
The following is a brief process description: a. When the operator pushes START, flash a
pilot light (PL) every 2 seconds to warn people that the conveyor belt is about to start. b.
After 80 seconds, start the conveyor motor, and turn off the pilot light. c. The operator
stops the conveyor line by pushing the STOP push button.
Modify Problem 19 to count the number of bags on the conveyor line, and stop the motor
after bags have passed. Add sensors as needed.
