PLC design using mitsubishi programmable logic controller (model GX ICE simulator)Problem
Produce a piece of ladder logic in GX IEC Simulator to control the following automated component checking process:
The device will allow manufactured components to be inserted to the test chamber through an entrance door. lithe component passes the check it can be removed through an exit door. otherwise it enters an alarm state.
1. The machine starts in an 'idle' state. The 'open_entry_door' output is activated to open the component insertion door. The bopen_exit_door' output is deactivated to close the component exit door.
2. When a component is inserted the 'component_ detected' input goes high. The 'open_entry_door' output should be deactivated to close the entry door.
3. When the 'entry_door_closed' and 4exit_door_closed' inputs are active it shows that both doors are shut. A 'start scan' output should then be set high to start a scan of the component. This is controlled by a separate device called the AutoMeasure2015.
4. When the scan of the component is complete a 'scan_donet input is set by the AutoMeasure2015. The 'start scan' output should then be turned off.
5. If the AutoMeasure2015 indicates a possible problem by setting a 'scan_failed. input to the PLC, or if it takes longer than five seconds to respond, then it goes to step 8, otherwise it goes to step 6.
Component check pass
6. The `open_exit_door output is activated to open the exit door. The machine waits until the `component_detected' input goes low.
7. The `open_exit_door' output is deactivated to close the door. The machine waits until the 'exit door closed' input is high before returning to the 'idle' state.
Alarm state
8. In the alarm state an indicator light is set to flash on and off at 4 Hz and a supervisor's 'key' must be active to allow steps 6 and 7.
9. After the component has been removed the 'key' must be removed before the flashing lamp is turned off, the door closes and the system returns to the 'idle' state.
An HMI in GX works is provided for you to test your logic. It is strongly advised that you study this HMI first to align your I/O designation to that of the HMI. Note that you will not need to use all the components in the HMI.
Tasks
Summarise your work with a brief report with approximately 5 pages of write-up and no more than 10 pages. Your report must include the following:
1) A table listing
a. each system input
b. each input type (e.g. normally open push-button)
c. the input number for your logic
d. each system output (e.g. signal to ComponentScan2015, motor coil, etc.)
e. each output type
f. the output number for your logic
2) A timing diagram for the 'alarm' state.
3 The to used to control the .rocess with suitable brie annotation
4) Comment on whether the communication between the PLC and ComponentScan2015 is "failsafe" so that is can be recovered in the event of an unexpected occurrence. If not, suggest what additional 110 should be provided to make the system more robust.
Your report should be considered as a "technical report" to management, so the introduction should not include general information about PLCs.