Keyence PLC Control for Washing Machine


The PLC used in this application is PLC Keyence KV series.
Here is a list of PLC inputs which will be connected with other external devices such as switch, sensors and so forth.
Here are the following names:

0000 : It will be connected with the push button with the name of START Auto Cycle.

0001 : It will be connected with the push button with the name of START 1 Cycle.

0002 : It will be connected with selector switch with the name of Water Spray OFF/ON which will be used to turn off and turn on the Jet Pump Motor.

0003 : It will be connected with the push button with the name of STOP Auto Cycle. The push button will have some functions not only to turn off the process of 1 Cycle and Auto Cycle but also used Emergency Stop.


0004 : It will be connected to proximity sensor which will be used as a sensor to detect the position from the glass bottle. The proximity sensor will read the position as many as 10 positions in one round. For proximity sensor reading, when the position of the glass bottle is outside from the water spray, the light will turn off or give the OFF signal. When the position of the glass is no longer outside from the water spray, the light will turn on or give the ON signal.

Here is a list of PLC outputs which will control some devices such as contactors, solenoid and so forth.
Here are the following names:

0500 : It will be connected to the contactor used to turn off or turn on the electric motor in TurnTable.

0501 : It will be connected to the contactor used to turn off or turn on the Jet Pump Motor

0502 : It will be connected to the solenoid valve used to stop or spout the water spray to the glass bottle.

After knowing both PLC inputs and PLC outputs connected or linked to other external devices, here is the plc programming used in the rotary bottle washing machine with the PLC Keyence as its main control. This PLC program will use standard sequence programming.

This Video about How To Create Keyence PLC Ladder for Rotary Bottle Washing Machine


Please click the link below to get the PDF file:
(in Google Docs: click File ---> click Download)

This program is created with KV builder from Keyence. For more information, here is the master file for the program in the form of RAR file. Please click the link below to download it:
(in Google Docs: click File ---> click Download)
Keyence-for-washing-machine(.rar)

After you have downloaded the file, I will help you learn how to read the ladder plc programming for rotary bottle washing machine.

1. INPUT CONDITION

1.1.a.
If plc input 003 turn on then internal relay 1000 turn on else internal relay 1000 turn off.
1.1.b.
If internal relay 1105 turn on and plc output 0501 turn off then internal relay 1000 turn on else internal relay 1000 turn off.
1.2.
If plc input 003 turn off and plc output 0502 turn off and plc output 0500 turn off then internal relay 1001 turn on else internal relay 1001 turn off.
1.3.
If plc input 0001 turn on then internal relay 1002 turn on else internal relay 1002 turn off.
1.4.
If plc input 0000 turn on then internal relay 1003 turn on and hold turn on.
1.5.
If plc input 0003 turn on then internal relay 1003 turn off.


2. TRIGGER AND SENSOR CONDITION

2.1.
If internal relay 1100 turn on and internal relay 1001 turn on and internal relay 1002 or 1003 turn on then internal relay 1004 turn on with one scan cycle time of plc. And if internal relay 1004 turn on then automatically internal relay 1101 turn on with controller.
2.2.
If internal relay 1101 turn on and plc output 0500 turn on then internal relay 1004 turn on with one scan cycle time of plc. And if internal relay 1004 turn on then automatically internal relay 1102 turn on with controller.
2.3.
If internal relay 1102 turn on and plc input 0004 turn on then internal relay 1004 turn on with one scan cycle time of plc. And if internal relay 1004 turn on then automatically internal relay 1103 turn on with controller.
2.4.
If internal relay 1103 turn on and plc input 0004 turn off then internal relay 1004 turn on with one scan cycle time of plc. And if internal relay 1004 turn on then automatically internal relay 1104 turn on with controller.
2.5.
If internal relay 1104 turn on and plc output 0500 turn off and timer T001 turn on then internal relay 1004 turn on with one scan cycle time of plc. And if internal relay 1004 turn on then automatically internal relay 1105 turn on with controller.
2.6.
If internal relay 1105 turn on and plc output 0501 turn on then internal relay 1004 turn on with one scan cycle time of plc. And if internal relay 1004 turn on then automatically internal relay 1106 turn on with controller.
2.7.
If internal relay 1106 turn on and plc output 0502 turn on then internal relay 1004 turn on with one scan cycle time of plc. And if internal relay 1004 turn on then automatically internal relay 1107 turn on with controller.
2.8.
If internal relay 1107 turn on and timer T002 turn on then internal relay 1004 turn on with one scan cycle time of plc. And if internal relay 1004 turn on then automatically internal relay 1108 turn on with controller.
2.9.
If internal relay 1108 turn on and plc output 0502 turn off and timer T003 turn on then internal relay 1004 turn on with one scan cycle time of plc. And if internal relay 1004 turn on then automatically internal relay 1100 turn on with controller.


3. OUTPUT CONDITION

3.1.
If internal relay 1104 turn on and plc output 0500 turn off then Timer T001 active, after 5 x100ms = 500ms(millisecond) timer T001 turn on. This timer for TurnTable STOP stability and Time can be set according to need.
3.2.
If internal relay 1107 turn on and plc output 0502 turn on then Timer T002 active, after 5 x100ms = 500ms(millisecond) timer T002 turn on. This timer for water spray on delay and Time can be set according to need.
3.3.
If internal relay 1108 turn on and plc output 0502 turn off then Timer T003 active, after 5 x100ms = 500ms(millisecond) timer T003 turn on. This timer for water spray off delay and Time can be set according to need.
3.4.a.
If internal relay 1100 turn off and internal relay 1101 turn on and internal relay 1104 turn off then plc output 0500 turn on and hold turn on.
3.4.b.
If internal relay 1100 or 1104 turn on then plc output 0500 turn off.
3.5.
If plc input 0002 turn on then plc output 0501 turn on else plc output 0501 turn off.
3.6.a.
If internal relay 1100 turn off and internal relay 1106 turn on and internal relay 1108 turn off then plc output 0502 turn on and hold turn on.
3.6.b.
If internal relay 1100 or 1108 turn on then plc output 0502 turn off.


4. CONTROLLER

4.1.
If internal relay 1100 to 1108 turn off then internal relay 1005 turn on else internal relay 1005 turn off.
4.2.
If internal relay 1005 turn on and counter C000 not equal 0 then counter C000 reset turn on or current value of counter C000 filled with 0.
4.3.
If special relay 2002 always on then counter C000 activated. Input counter use internal relay 1004 and maximum 1000 counting.
4.4.
If internal relay 1000 turn on then counter C000 reset turn on or current value of counter C000 filled with 0.
4.5.
If special relay 2002 always on and read data from counter C000 and compare with value 0 to 8.Result compare used for turn on/off internal relay. The following are the conditions of the comparison :
• If counter C000 equal 0 then internal relay 1100 turn on else internal relay 1100 turn off.
• If counter C000 equal 1 then internal relay 1101 turn on else internal relay 1101 turn off.
• If counter C000 equal 2 then internal relay 1102 turn on else internal relay 1102 turn off.
• If counter C000 equal 3 then internal relay 1103 turn on else internal relay 1103 turn off.
• If counter C000 equal 4 then internal relay 1104 turn on else internal relay 1104 turn off.
• If counter C000 equal 5 then internal relay 1105 turn on else internal relay 1105 turn off.
• If counter C000 equal 6 then internal relay 1106 turn on else internal relay 1106 turn off.
• If counter C000 equal 7 then internal relay 1107 turn on else internal relay 1107 turn off.
• If counter C000 equal 8 then internal relay 1108 turn on else internal relay 1108 turn off.


Here is the description for rotary bottle washing machine:
1. Waiting All Origin and Waiting Start 1 Cycle or Auto Cycle.
2. TurnTable RUN to next point position.
3. Check proximity sensor: Check ON condition.
4. Check proximity sensor: Check OFF condition.
5. TurnTable STOP and waiting stability timer.
6. Check Jet Pump Motor (Water Spray) : If jet pump motor turn off then goto waiting start 1 cycle or auto cycle (no.1) else goto solenoid valve turn on (no.7).
7. Solenoid Valve turn on.
8. Delay for Solenoid Valve turn on.
9. Solenoid Valve turn off and Delay.

Hopefully this plc tutorial would be really helpful in helping you all learn about plc programming. I would like to say thank you for visiting my blog.
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