Block Tester

Description of project (worth 10% towards final grade) The objective of this project is to test a variety of round objects and sort them according to the type of construction material and colour. One reflective sensor is used to determine that block is in position, three other proximity sensors determine whether block is made of plastic, Aluminum or a Ferris material. The smart sensor is programmed to operate one of three outputs depending on the colour of the object. These are wired to three separate PLC inputs (details below).

Figure 1 Block testing device

Figure 2 Block testing device and Festo connecting hardware

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Project 1 - Block Testing Requirements (a) Prepare either a written description of the program operation, or a diagram illustrating the program operation. (b) Prepare an I/O listing for each block type: Black Plastic, Orange Plastic, White Plastic, Aluminium, Steel. (See template below) All sensors are wired NO, except the Block in Place sensor which is NC. Program requirements: (c) Create a program to read the PLC inputs and produce unique binary value for each block in the data register [D000] memory of the PLC. Assign one internal memory bit (M..) for each block type; show this in your table for part b. These memory bits should be within a continuous set of 16 internal relays; eg M0020 M0037 (28,29 are not included because of Octal numbering). Use the appropriate sensor inputs to PLC to control the memory bits (refer to your table, part b) Include basic error protection; ie Black and White sensors shouldnt be on simultaneously. Use the Move function in your ladder to transfer the data from memory bits to data register. (see example on next page) The complete data register can be transferred via a network to another machine (not in the scope of this project) (d) Use the bits in memory to turn ON the corresponding PLC output. The sensors are wired to produce a source 24V output. Sensors I0000 I0001 I0002 I0003 I0004 I0005 I0006 Data Register Bits D000.00 Plastic D000.01 Aluminium D000.02 Steel D000.03 Black D000.04 Orange D000.05 White D000.06 Error Outputs Required Q0000 Black Plastic Block Light Q0001 Orange Plastic Block Q0002 White Plastic Block Light Q0003 Aluminum Block Light Q0004 Steel Block Light Q0005 Error Light

Block In Place Plastic Block Combination Steel Block Black Colour Orange Colour White Colour

Template for part b: Input states I000 I001 Outputs I002 I003 I004 I005 I006
(State which is active)

Block Type Black Plastic

Memory bit

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Project 1 - Block Testing Example of Move function:

16 bits of data are copied:

M0020 21 22 23 24 25 26 27 30 31 32 33 34 35 36 37 D000 .00 .01 .02 .03 .04 .05 .06 .07 .10 .11 .12 .13 .14 .15 .16 .17

Copy Data

Assessment Details

Marks Part A - Explanation of sequence of your ladder software operation. (written / diagram) Part B Part C Part D Documentation of PLC software rungs (comments) Total 5

2 4 5 4 20

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Project 1 - Block Testing

Project 1 - Block Testing

Project 1 - Block Testing

Project 1 - Block Testing

Project 1 - Block Testing

Project 1 - Block Testing