Chair of Machine Tools

Prof. Dr.-Ing. Christian Brecher

Excercise 3

Mechatronics and control for production plants

Topic:

PLC and Motion Control - Solution

Assistant
responsible:

Jerome Flender, M.Sc.

J.Flender@wzl.rwth-aachen.de
WZL, 53B R401
Phone: 0241 / 80-27458

Content
1.

2.

3.

Tasks information processing

1.1.

Task 1

1.2.

Task 2

1.3.

Task 3

Tasks machine controls

2.1.

Task 4

2.2.

Task 5

2.3.

Task 6

2.4.

Task 7

2.5.

Task 8

References

PLC and Motion Control, Mechatronics and control for production plants

1. Tasks information processing

1.1.

Task 1

Prove by means of algebraic transformation but without using theorem 10 - that

X Y X Z X Y Z .
Option 1

Option 2

X Y X Z

XX XZ YX YZ [exp anded ]

[ Th.10]

X YZ XZ YX [ simplified ]

X Y X X Y Z

X XZ YX YZ [rearranged ]

[ Th.10]
X (X Y ) (X Z) (Y Z)

[Th.7]
X YX YZ
[Th.7]
X YZ
q.e.d .

[ Th.7 ]
X (X Z) (Y Z)
[ Th.7 ]
X YZ
q.e.d.

1.2.

Task 2

Consider the following circuit::

1100

1
1

0010

C
0001

Q
1001

B
1010

0100

PLC and Motion Control, Mechatronics and control for production plants

Determine the logical equation for Q = f(A,B)

a) using a truth table
A
0
0
1
1

B
0
1
0
1

Q
1
0
0
1

Q A B A B

b) using the theorems of Boolean algebra

Theorem 13
Theorem 4`
Theorem 10`

Q A C B C u sin g C A B
ACB C
( A C) (B C)
A B C

C A B

Theorem 13

A B A B
A B A B
c) What ist the resulting function?
XNOR (exclusive Not-Or),
Equivalent circuit diagram:

=1

1.3.

or

Task 3

The functionality of a door lock is described by the following truth table.

Input 1 (A)

Input 2 (B)

Input 3 (C)

Input 4 (D)

Output (Q)

PLC and Motion Control, Mechatronics and control for production plants

Using a Karnaugh map, please derive the disjunctive normal form of the function Q.

Q = CD + A C D + A BC

PLC and Motion Control, Mechatronics and control for production plants

2. Tasks machine controls

2.1.

Task 4

The relay circuit used to control a feed drive and depicted in Figure 2-1 is given. The
feed drive permits three movements: rapid feed forward, rapid feed backward and
feed forward, each switched by a push-button control.

p S1 Lubrication
pressure

m1

p S2 Hydraulic

a2.1
a3.1

a1.1

S3 Rapid feed backward

ON

S4 End position - back

reached

M1 Help relais

A1 Rapid feed backward

a1.2
S5 End position - front
reached

S6 Rapid feed forward

ON

a3.2

A2 Rapid feed forward

S7 Feed forward
ON

a2.2

A3 Feed forward

Figure 2-1: Realising a feed control in relay technology

Briefly explain the difference between an operation and a sequencing control and
state which of these two types of control is represented by the feed control system in
Figure 2-1.
A sequence control always adheres to a strict order of processing. Operation controls
work based on the Theorems of Boolean Algebra according to the programmed
code. The order of execution is arbitrary.
The current use case incorporates an operation control as upon activation of the
helping relais M1 the order of execution of the remaining function is arbitrary.

PLC and Motion Control, Mechatronics and control for production plants

2.2.

Task 5

The circuit in Figure 2-1 includes self-holding and interlocking functions for the individual movements (rapid feed forward, rapid feed backward, feed forward). Which
contacts perform interlocking and which perform self-holding?
Self-holding function: a1.1
Interlocking function: a1.2, a2.1, a2.2, a3.1, a.3.2

2.3.

Task 6

Infer from the circuit diagram in Figure 2-1 the logical equations for the three movements (rapid feed forward, rapid feed backward, feed forward). Use the switch (S1 to
S7) and relay (M1 and A1 to A3) designations given in the figure.

Rapid feed backward:

A1 M1 A2 A 3 (S3 A1) S4 considering M1 S1 S2

Rapid feed forward:

A2 M 1 A1 S 5 S 6 A3
Feed forward:
A 3 M1 A1 S5 S7 A2

2.4.

Task 7

In the following the relay control in Figure 2-1 is to be replaced by a PLC. Therefore,
a PLC programme has to written according to the equations of task 6.
The push buttons (S) and relays (A) are allocated to the inputs (E), outputs (A),
and labels (M) as follows:
S1 up to S7 =
A1 up to A3 =
M1
=

I1 up to I7
Q1 up to Q3
M1

PLC and Motion Control, Mechatronics and control for production plants

Write the PLC program as an Instruction List (IL) for the rapid feed backward
movement (Q1).

A
A
=

I1
I2
M1

A
AN
AN
A(
A
O
)
AN

M1
Q2
Q3

I3
Q1
I4
Q1

Write the PLC program as a Function Block Diagram (FBD) for the rapid feed
forward movement (Q2).
I1
&

I2

M1
&

Q1

Q2

I5

I6
Q3

Write the PLC program as a Ladder Diagram (LD) for the feed forward movement (Q3).
I1

I2

M1

Q1

M1

I5

I7

Q2

Q3

PLC and Motion Control, Mechatronics and control for production plants

2.5.

Task 8

Figure 2-2: Control of a sequenced packaging plant

As it is shown in the figure above two light barriers are installed on the conveyor. The
first light barrier (LS1) is installed in the robot-work-cell and the second one (LS2)
near to the scale module. If no package is detected between the transmitter and the
receiver, a true-signal is sent by the light barrier.
To start the sequence the operator has to push an empty package into the robot
work cell. If the empty package is detected, the robot starts packaging six bottles in
exactly six seconds. Afterwards the operator shifts this package onto the scale module and this control element determines the actual weight of the package (Gp). If it is
equal to a predefined weight G1, the package is shifted along path B1; otherwise the
packing is shifted along path B2 to examine the package manually. The switchgear
for the path selection is controled by a pneumatic cylinder (see picture).

PLC and Motion Control, Mechatronics and control for production plants

Figure 2.1: Functionality of a pneumatic cylinder

If the package has to be moved along path B1, the cylinder gets a "0"-signal and
moves left-hand. The package is moved along path B2 if the cylinder gets a high signal (logical "1 "-signal).
Please write a control program using SCL.
0
Init

LS1 = 0

Belt conveyor

Robot start packing

Timer start

Timer stop

Robot stop packing

Belt conveyor

Belt conveyor

Scale of
weights

Start scale of weights

1
Packing
t = 6s

2
Redirect
LS2 = 0

Gp G1

Gp = G1
S

Belt conveyor

B1, Cylinder L

4a

4b

Redirect

Sort out

Belt conveyor

B2, Cylinder R

5
Back to 0

PLC and Motion Control, Mechatronics and control for production plants

3. References
[1]

Weck, M.: Werkzeugmaschinen und Fertigungssysteme Band 4,

VDI-Verlag, Dsseldorf, 1996.

[2]

Boole, G.: The Mathematical Analysis of Logic.

Basil Blackwell, Oxford, 1965

[3]

Dworatscheck, S.: Grundlagen der Datenverarbeitung.

de Gruyter-Verlag, Berlin, 1986

[4]

Wolf, G.: Digitale Elektronik.

Franzis-Verlag, Mnchen, 1977

[5]

Eckl, Ptgens u. Walter: A/D- und D/A-Wandler; Grundlagen, Prinzipschaltungen und Applikationen.
Franzis-Verlag, Mnchen, 1990

[6]

Tietze u. Schenk: Halbleiter-Schaltungstechnik.

Springer-Verlag, Berlin, 1993

[7]

John, K-H., Tiegelkamp, M.: SPS-Programmierung mit 61131-3,

Springer Verlag, 2009