Monday, February 13, 2012

Allen Bradley PLC Control for Automatic Welding

PLC Type 1761 MicroLogix 1000, Name of the Input/Output:

I:0/0 ; Emergency Push Button
I:0/1 ; Push Button Start
I:0/2 ; Safety Sensor
I:0/3 ; Limit Switch Clamp Left Reverse
I:0/4 ; Limit Switch Clamp Left Middle
I:0/5 ; Limit Switch Clamp Left Forward
I:0/6 ; Limit Switch Clamp Right Reverse
I:0/7 ; Limit Switch Clamp Right Middle
I:0/8 ; Limit Switch Clamp Right Forward
I:0/9 ; Limit Switch Ejector Up
I:0/10 ; Limit Switch Ejector Down
I:0/11 ; Limit Switch Nozzle Reverse
I:0/12 ; Limit Switch Nozzle Middle
I:0/13 ; Limit Switch Nozzle Forward

O:0/0 ; Contactor to Torch Button of MIG Welding
O:0/1 ; Solenoid to Clamp Left Reverse
O:0/2 ; Solenoid to Clamp Left Forward
O:0/3 ; Solenoid to Clamp Right Reverse
O:0/4 ; Solenoid to Clamp Right Forward
O:0/5 ; Solenoid to Ejector Up
O:0/6 ; Solenoid to Ejector Down
O:0/7 ; Solenoid to Nozzle Reverse
O:0/8 ; Solenoid to Nozzle Forward

Download PDF File:
Allen Bradley PLC for Automatic Welding Machine(.pdf)

Please Download Programming for RSLogix Micro Starter Lite :
Allen Bradley PLC Control for Automatic Welding

Reading Ladder PLC Programming for Automatic Welding Using Standard Sequence Programming:


1.1. Waiting Start=ON
1.1.a.If I:0/0=ON OR (B3:1/0=OFF AND I:0/2=OFF) Then B3:0/0 = ON
1.1.b.If B3:0/0 = ON Then RES C5:0 or C5:0.ACC = 0 (Only STEP0 = ON)

1.2. All Origin=ON
If I:0/0=OFF AND I:0/2=ON AND I:0/3=ON AND I:0/6=ON AND I:0/9=ON AND I:0/11=ON Then B3:0/1=ON

1.3. Start=ON
If I:0/0=OFF AND I:0/2=ON AND I:0/1=ON Then B3:0/2=ON


2.1. Waiting Start=ON
2.1.a. If C5:0.ACC=0 Then B3:1/0=ON
2.1.b. If B3:1/0=ON AND B3:0/1=OFF AND B3:0/2=OFF Then B3:1/0=ON

2.2. Waiting Start=OFF, And Movement1=ON
If B3:1/0=ON AND B3:0/1=ON AND B3:0/2=ON Then B3:0/3=ON, C5:0.ACC=1, B3:1/0=OFF, B3:1/1=ON

2.3. Movement1=ON
2.3.a. If C5:0.ACC=1 Then B3:1/1=ON
2.3.b. If B3:1/1=ON AND B3:0/6=OFF AND B3:0/7=OFF Then B3:1/1=ON

2.4. Movement1=OFF, And Movement2=ON
If B3:1/1=ON AND B3:0/6=ON AND B3:0/7=ON Then B3:0/3=ON, C5:0.ACC=2, B3:1/1=OFF, B3:1/2=ON

2.5. Movement2=ON
2.5.a. If C5:0.ACC=2 Then B3:1/2=ON
2.5.b. If B3:1/2=ON AND I:0/10=OFF Then B3:1/2=ON

2.6. Movement2=OFF, And Movement3=ON
If B3:1/2=ON AND I:0/10=ON Then B3:0/3=ON, C5:0.ACC=3, B3:1/2=OFF, B3:1/3=ON

2.7. Movement3=ON
2.7.a. If C5:0.ACC=3 Then B3:1/3=ON
2.7.b. If B3:1/3=ON AND I:0/5=OFF AND I:0/8=OFF Then B3:1/3=ON

2.8. Movement3=OFF, And Movement4=ON
If B3:1/3=ON AND I:0/5=ON AND I:0/8=ON Then B3:0/3=ON, C5:0.ACC=4, B3:1/3=OFF, B3:1/4=ON

2.9. Movement4=ON
2.9.a. If C5:0.ACC=4 Then B3:1/4=ON
2.9.b. If B3:1/4=ON AND I:0/12=OFF Then B3:1/4=ON

2.10. Movement4=OFF, And Movement5=ON
If B3:1/4=ON AND I:0/12=ON Then B3:0/3=ON, C5:0.ACC=5, B3:1/4=OFF, B3:1/5=ON

2.11. Movement5=ON
2.11.a. If C5:0.ACC=5 Then B3:1/5=ON
2.11.b. If B3:1/5=ON AND I:0/13=OFF Then B3:1/5=ON

2.12. Movement5=OFF, And Movement6=ON
If B3:1/5=ON AND I:0/13=ON Then B3:0/3=ON, C5:0.ACC=6, B3:1/5=OFF, B3:1/6=ON

2.13. Movement6=ON
2.13.a. If C5:0.ACC=6 Then B3:1/6=ON
2.13.b. If B3:1/6=ON AND I:0/12=OFF Then B3:1/6=ON

2.14. Movement6=OFF, And Movement7=ON
If B3:1/6=ON AND I:0/12=ON Then B3:0/3=ON, C5:0.ACC=7, B3:1/6=OFF, B3:1/7=ON

2.15. Movement7=ON
2.15.a. If C5:0.ACC=7 Then B3:1/7=ON
2.15.b. If B3:1/7=ON AND I:0/11=OFF Then B3:1/7=ON

2.16. Movement7=OFF, And Movement8=ON
If B3:1/7=ON AND I:0/11=ON Then B3:0/3=ON, C5:0.ACC=8, B3:1/7=OFF, B3:1/8=ON

2.17. Movement8=ON
2.17.a. If C5:0.ACC=8 Then B3:1/8=ON
2.17.b. If B3:1/8=ON AND B3:0/6=OFF AND B3:0/7=OFF Then B3:1/8=ON

2.18. Movement8=OFF, And Movement9=ON
If B3:1/8=ON AND B3:0/6=ON AND B3:0/7=ON Then B3:0/3=ON, C5:0.ACC=9, B3:1/8=OFF, B3:1/9=ON

2.19. Movement9=ON
2.19.a. If C5:0.ACC=9 Then B3:1/9=ON
2.19.b. If B3:1/9=ON AND I:0/3=OFF AND I:0/6=OFF Then B3:1/9=ON

2.20. Movement9=OFF, And Movement10=ON
If B3:1/9=ON AND I:0/3=ON AND I:0/6=ON Then B3:0/3=ON, C5:0.ACC=10, B3:1/9=OFF, B3:1/10=ON

2.20. Movement10=ON
2.20.a. If C5:0.ACC=10 Then B3:1/10=ON
2.20.b. If B3:1/10=ON AND I:0/9=OFF Then B3:1/10=ON

2.21. Movement10=OFF, And Waiting Start=ON
If B3:1/10=ON AND I:0/9=ON Then B3:0/3=ON, C5:0.ACC=0, B3:1/10=OFF, B3:1/0=ON


3.1. Hold ON for Limit Switch Clamp Left Middle
If (B3:1/1=ON OR B3:1/8=ON) AND I:0/4=ON Then Latch(L) B3:0/6 (B3:0/6=ON Hold)

3.2. Hold ON for Limit Switch Clamp Right Middle
If (B3:1/1=ON OR B3:1/8=ON) AND I:0/7=ON Then Latch(L) B3:0/7 (B3:0/7=ON Hold)

3.2. Hold OFF for Limit Switch Clamp Left/Right Middle
If B3:1/2=ON OR B3:1/9=ON OR B3:1/0=ON Then Unlatch(U) B3:0/6 (B3:0/6=OFF), Unlatch(U) B3:0/7 (B3:0/7=OFF)

3.3. Torch Button of MIG Welding=ON
If B3:1/5=ON Then O:0/0=ON

3.4. Solenoid to Clamp Left Reverse=ON
If (B3:1/8=ON AND B3:0/6=OFF) OR B3:1/9=ON Then O:0/1=ON

3.5. Solenoid to Clamp Left Forward=ON
If (B3:1/1=ON AND B3:0/6=OFF) OR B3:1/3=ON Then O:0/2=ON

3.6. Solenoid to Clamp Right Reverse=ON
If (B3:1/8=ON AND B3:0/7=OFF) OR B3:1/9=ON Then O:0/3=ON

3.7. Solenoid to Clamp Right Forward=ON
If (B3:1/1=ON AND B3:0/7=OFF) OR B3:1/3=ON Then O:0/4=ON

3.8. Solenoid to Ejector Up=ON
If B3:1/10=ON Then O:0/5=ON

3.9. Solenoid to Ejector Down=ON
If B3:1/2=ON Then O:0/6=ON

3.10. Solenoid to Nozzle Reverse=ON
If B3:1/6=ON OR B3:1/7=ON Then O:0/7=ON

3.10. Solenoid to Nozzle Forward=ON
If B3:1/4=ON OR B3:1/5=ON Then O:0/8=ON


2.1. Waiting Start=ON
2.1.a.If B3:1/1=OFF AND B3:1/2=OFF AND B3:1/3=OFF AND B3:1/4=OFF AND B3:1/5=OFF AND B3:1/6=OFF AND B3:1/7=OFF Then B3:0/4=ON
2.1.b.If B3:0/4=ON AND B3:1/8=OFF AND B3:1/9=OFF AND B3:1/10=OFF Then B3:0/5=ON
2.1.c.If B3:0/5=ON AND C5:0.ACC Not Equal 0 (Null) Then RES C5:0 or C5:0.ACC = 0 (Only STEP0 = ON)
2.1.b.If C5:0.ACC=0 Then B3:1/0=ON

2.2. Trigger to Count of C5:0
If B3:0/3 = ON Then Count Up C5:0 = ON

2.3. Emergency Stop=ON
If B3:0/0 = ON Then RES C5:0 or C5:0.ACC = 0 (Only STEP0 = ON)

2.4. Waiting Start=ON, And Movement1=ON Up to Movement10=ON
2.4.a.If C5:0.ACC=0 Then B3:1/0=ON (Waiting Start=ON)
2.4.b.If C5:0.ACC=1 Then B3:1/1=ON (Movement1=ON)
2.4.c.If C5:0.ACC=2 Then B3:1/2=ON (Movement2=ON)
2.4.d.If C5:0.ACC=3 Then B3:1/3=ON (Movement3=ON)
2.4.e.If C5:0.ACC=4 Then B3:1/4=ON (Movement4=ON)
2.4.f.If C5:0.ACC=5 Then B3:1/5=ON (Movement5=ON)
2.4.g.If C5:0.ACC=6 Then B3:1/6=ON (Movement6=ON)
2.4.h.If C5:0.ACC=7 Then B3:1/7=ON (Movement7=ON)
2.4.i.If C5:0.ACC=8 Then B3:1/8=ON (Movement8=ON)
2.4.j.If C5:0.ACC=9 Then B3:1/9=ON (Movement9=ON)
2.4.k.If C5:0.ACC=10 Then B3:1/10=ON (Movement10=ON)

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

Back to : Automatic Welding Machine


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