Thursday, May 24, 2012

Mitsubishi PLC Control for Washing Machine




The PLC used in this application is PLC Mitsubishi FX 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:

X000 : It will be connected with the push button with the name of START Auto Cycle.

X001 : It will be connected with the push button with the name of START 1 Cycle.

X002 : 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.

X003 : 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.


X004 : 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:

Y000 : It will be connected to the contactor used to turn off or turn on the electric motor in TurnTable.

Y001 : It will be connected to the contactor used to turn off or turn on the Jet Pump Motor

Y002 : 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 Mitsubishi as its main control. This PLC program will use standard sequence programming. Please click the image below to get the PDF file:
(in Google Docs: click File ---> click Download)

This program is created with GX Developer from Mitsubishi. For more information, here is the master file for the program in the form of ZIP file. Please click the link below to download it:
(in Google Docs: click File ---> click Download)
Mitsubishi-washing-machine(.zip)

Video about make plc ladder for this application:


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 X003 turn on then internal relay M0 turn on else internal relay M0 turn off.
1.1.b.
If internal relay M15 turn on and plc output Y001 turn off then internal relay M0 turn on else internal relay M0 turn off.
1.2.
If plc input X003 turn off and plc output Y002 turn off and plc output Y000 turn off then internal relay M1 turn on else internal relay M1 turn off.
1.3.
If plc input X001 turn on then internal relay M2 turn on else internal relay M2 turn off.
1.4.
If plc input X000 turn on then internal relay M3 turn on and hold turn on.
1.5.
If plc input X003 turn on then internal relay M3 turn off.


2. TRIGGER AND SENSOR CONDITION

2.1.
If internal relay M10 turn on and internal relay M1 turn on and internal relay M2 or M3 turn on then internal relay M4 turn on with one scan cycle time of plc. And if internal relay M4 turn on then automatically internal relay M11 turn on with controller.
2.2.
If internal relay M11 turn on and plc output Y000 turn on then internal relay M4 turn on with one scan cycle time of plc. And if internal relay M4 turn on then automatically internal relay M12 turn on with controller.
2.3.
If internal relay M12 turn on and plc input X004 turn on then internal relay M4 turn on with one scan cycle time of plc. And if internal relay M4 turn on then automatically internal relay M13 turn on with controller.
2.4.
If internal relay M13 turn on and plc input X004 turn off then internal relay M4 turn on with one scan cycle time of plc. And if internal relay M4 turn on then automatically internal relay M14 turn on with controller.
2.5.
If internal relay M14 turn on and plc output Y000 turn off and timer T1 turn on then internal relay M4 turn on with one scan cycle time of plc. And if internal relay M4 turn on then automatically internal relay M15 turn on with controller.
2.6.
If internal relay M15 turn on and plc output Y001 turn on then internal relay M4 turn on with one scan cycle time of plc. And if internal relay M4 turn on then automatically internal relay M16 turn on with controller.
2.7.
If internal relay M16 turn on and plc output Y002 turn on then internal relay M4 turn on with one scan cycle time of plc. And if internal relay M4 turn on then automatically internal relay M17 turn on with controller.
2.8.
If internal relay M17 turn on and timer T2 turn on then internal relay M4 turn on with one scan cycle time of plc. And if internal relay M4 turn on then automatically internal relay M18 turn on with controller.
2.9.
If internal relay M18 turn on and plc output Y002 turn off and timer T3 turn on then internal relay M4 turn on with one scan cycle time of plc. And if internal relay M4 turn on then automatically internal relay M10 turn on with controller.


3. OUTPUT CONDITION

3.1.
If internal relay M14 turn on and plc output Y000 turn off then Timer T1 active, after 5 x100ms = 500ms(millisecond) timer T1 turn on. This timer for TurnTable STOP stability and Time can be set according to need.
3.2.
If internal relay M17 turn on and plc output Y002 turn on then Timer T2 active, after 100 x100ms = 10000ms(millisecond) / 10 second timer T2 turn on. This timer for water spray on delay and Time can be set according to need.
3.3.
If internal relay M18 turn on and plc output Y002 turn off then Timer T3 active, after 5 x100ms = 500ms(millisecond) timer T3 turn on. This timer for water spray off delay and Time can be set according to need.
3.4.a.
If internal relay M10 turn off and internal relay M11 turn on and internal relay M14 turn off then plc output Y000 turn on and hold turn on.
3.4.b.
If internal relay M10 or M14 turn on then plc output Y000 turn off.
3.5.
If plc input X002 turn on then plc output Y001 turn on else plc output Y001 turn off.
3.6.a.
If internal relay M10 turn off and internal relay M16 turn on and internal relay M18 turn off then plc output Y002 turn on and hold turn on.
3.6.b.
If internal relay M10 or M18 turn on then plc output Y002 turn off.


4. CONTROLLER

4.1.
If internal relay M11 to M18 turn off then internal relay M5 turn on else internal relay M5 turn off.
4.2.
If internal relay M5 turn on and counter C not equal 0 then counter C0 reset turn on or current value of counter C0 filled with 0.
4.3.
If internal relay M4 turn on then counter C000 activated. Input counter use internal relay M4 and maximum 1000 counting.
4.4.
If internal relay M0 turn on then counter C0 reset turn on or current value of counter C0 filled with 0.
4.5.
Read data from counter C0 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 C0 equal 0 then internal relay M10 turn on else internal relay M10 turn off.
• If counter C0 equal 1 then internal relay M11 turn on else internal relay M11 turn off.
• If counter C0 equal 2 then internal relay M12 turn on else internal relay M12 turn off.
• If counter C0 equal 3 then internal relay M13 turn on else internal relay M13 turn off.
• If counter C0 equal 4 then internal relay M14 turn on else internal relay M14 turn off.
• If counter C0 equal 5 then internal relay M15 turn on else internal relay M15 turn off.
• If counter C0 equal 6 then internal relay M16 turn on else internal relay M16 turn off.
• If counter C0 equal 7 then internal relay M17 turn on else internal relay M17 turn off.
• If counter C0 equal 8 then internal relay M18 turn on else internal relay M18 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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