Regina Wayi B Tech INS 3A INS 322
INS 322 – Programmable Logic Controller (PLC) and AC/DC Controls
Assessment Type: Mitsubishi PLC Programming portfolio
Beginners Level
1. Paging Unit
Control objective: To control the paging unit of a restaurant
Circuit operation: The paging unit is operated using three relays and two push buttons labeled X000 and
YOO1 to actuate the paging unit for table 1 and 2 with relay contacts of Y000 and Y001 to control the
call indicator on the restaurant wall respectively. It has reset open contact which is labeled X020 with a
relay contact Y023 to change the control unit back to its normal position.
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2. Detect Sensor Light
Control objective: Turn the flashing lights ON when an object is detected
Circuit operation: The Detect Sensor Light is operated using 2 relays and 3 timers. The 2 relays
are used to control the person moving and the car driving into the pink coloured area. T1 is set
for the falling impulse contact X001 (X1). This means that when the person enters Y1 comes ON
and when he/she leaves Y0 comes ON after 5 seconds. T2 is set for the open contact X002 (X2).
When the car drives and is positioned in the pink area Y004 (Y4) comes ON but after 1 minute
the buzzer Y007 (Y7) comes ON. Both automatically turn off after exiting sensor X3.
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3. Time Control for Traffic Light
Control objective: Control a traffic light where the signals are changed at specific time intervals
Circuit operation: At the press of normally contact X020 (X20) of PB1 the red light (Y0) comes ON
and turns OFF after 10 seconds from T1. Yellow light (Y1) automatically comes ON and turns OFF
after 5 seconds from T2. Followed by the green light (Y2) being ON and turning OFF after 10
seconds. The cycle of the time control for the traffic light is run continuously with stopping.
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4. Part Sorting by Size (i)
Control objective: Sort different sized parts using sensors
Circuit operation: When PB1 is pressed its normally open contact XO10 (X10) linked to the
replay contact Y005 (Y5) supplies the command for the robot arm to pick up the 3 different sizes
[Small (Y12), Medium (Y11) & Large (Y10)] of boxes. The conveyor Y003 (Y3) moves forward to
the right after the normally open contact X014 (X14) is switched ON. The boxes pass through 3
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different levels of sensors X002 (X2) for lower, X001 (X1) for middle and X000 (X0) for upper in
order to sort the different sizes of boxes. After light has been lit for the sensors, the boxes are
distributed accordingly in station X004 (X4) as the falling impulse is energized.
5. Conveyor Start/Stop
Control objective: Start and stop the conveyor according to the predetermined procedure
Circuit operation: When PB1 on the operation panel is pressed it switches the normally open
contact of X020 (X20) ON. This turns the yellow light Y007 (Y7) ON and the buzzer Y003 (Y3) ON
for 5 seconds. After the 5 seconds is up for the buzzer the green light Y006 (Y6) is ON at the
same time the conveyor Y001 (Y1) moves forward. When PB2 is pressed it turns the green light
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OFF and stops the conveyor from moving because the normally closed contact of X021 is
opened.
6. Conveyor Drive
Control objective: Operate the conveyor according to the sensor data
Circuit operation: When PB1 is pressed on the operation panel the rising pulse of XO20 actuates
the normally open contact of the starting point X005 (X5) and supplies command to the robot
arm to lift the boxes to towards the upper conveyor. As soon as the box is detected by sensor
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X000 (X0) it turns the conveyor forward Y000 (Y0). The same concept applies for the middle
conveyor and lower conveyor but with different sensor and relay contact attached. When the
box passes through sensor X003 (X3) it automatically triggers the starting point to supply the
next box in the same process.
Intermediate Level
1. Pushbutton Signal
Control objective: Switch the traffic signals in response to a pushbutton
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Circuit operation: Initially the red light flickers ON and OFF in a 1 second interval using T0 and
T1. When the pink pushbutton is pressed on the operation panel, the yellow signal light Y010
(Y1) is ON for 5 seconds. Then the green signal light Y002 (Y2) is ON for 10 seconds. After 10
seconds, the red light Y000 (Y0) comes ON again in its initial state by flickering. Until the pink PB
is pressed, the signal lights are turned ON accordingly.
2. Part Sorting by Size (ii)
Control objective: Distribute each part to its proper destination according to its size
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Circuit operation: When SW1 is turned ON, it switches the normally open contact of X024 (X24)
to close by causing the conveyor YOO1 (Y1) to move forward to the right. At the press of PB1,
the rising pulse X020 (X20) interchanges and supplies command for the robot arm to transport
the different sizes of boxes onto the moving conveyor. The level sensors [X003 (X3) for lower,
X002 (X2) for middle and X001 (X1) for upper] on the conveyor detects the box size and sends
the message to the sorting wing YOO5 (Y5) open the sorting designation. The sorting station
with sensor XOO5 (X5) is designed for large boxes and with sensor XOO4 (X4) is for smaller sized
boxes. The process continues until it is stopped at the press of the reset button on the remote.
3. Part Separation
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Control objective: Give the command to a robot to move a part to a new location
Circuit operation: Initially the conveyor with relay coil YOO1 (Y1) is already moving forward to
the right. When PB1 is pressed on the operation panel it firstly turns ON the indicator ‘Supply
allowed’ in order to command for the operator to supply a part onto the moving conveyor. As
soon as the part has reached the part on the table X001 (X1), it actuates the unload command of
relay coil YOO2 (Y2) causing the robot arm to operate by transporting the part to the next
station or location behind for separation. After transportation, the robot operation finishes
because the normally closed contact of X002 (X2) interchanges or switches to a normally open
state.
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4. Drilling
Control objective: Control the drill and other devices
Circuit operation: When PB1 is pressed on the operation panel the open contact X020 (X20)
interchanges position causing the relay coil Y000 (Y0) to supply command for the part to be
transported to the conveyor YOO1 (Y1). The conveyor moves forward to the right after SW1 is
switched ON where normally open contact of X024 (X24) becomes a closed contact. When the
sensor detects part under drill XOO1 (X1), it stops the conveyor and the relay coil Y002 (Y2) is
ON allowing the drilling X000 (X0) to take place. The sensor X002 (X2) will indicate correct
drilling and the sensor X003 (X3) will indicate wrong drilling. As for sensor X005 (X5) it indicates
the object passing into the panel after the drilling operation. To start the drilling operation
again, PB1 has to be pressed again.
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5. Part Supply Control
Control objective: Supply a specified number of parts according to the control specifications
Circuit operation: When PB1 is pressed on the operation panel, the rising pulse of X020 (X20)
changes position causing the starting point XOOO (X0) to turn ON and the relay coil Y000 (Y0) to
supply the command for the part to be transported to the conveyor Y001 (Y1) by the robot arm.
The conveyor moves forward to the right when SW1 is turned ON. It stops when the sensor for
box on conveyor X001 (X1) is ON. At that same moment sensor X002 (X2) counts 5 oranges and
supplies it into the empty box. After the 5 th orange is supplied, the conveyor starts moving
forward again passing through sensor X005 (X5) which indicates its moving towards the tray.
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6. Conveyor Control
Control objective: Move the conveyor forward or backward according to the control
specifications
Circuit operation: When PB1 is pressed on the operation panel, it energizes the relay coil Y010
(Y10) supplying command for a part to be provided by the hopper towards the conveyor. The
object automatically moves to the right limit sensor X011 (X11) for a second and then moves to
the left limit sensor X010 (X10) for 5 seconds. After 5 seconds is over, the object moves to the
right where the stop sensor X012 (X12) is. All these conveyor movement is controlled only by
pressing PB2 which is the rising pulse contact in the ladder program.
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Advance Level
1. Automatic Door Operation
Control objective: Control the door which opens or closes when detecting an object
Circuit operation: When the in gate sensor X002 (X2) detects the car it energizes the relay coil
for the door up Y000 (Y0) at the same time the buzzer Y007 (Y7) sounds as the door is in motion.
When the car is in the range of the in gate and out sensor the light Y006 (Y6) turns ON until the
car is out of range. The door moves down when the out sensor X003 (X3) is turned OFF. The
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door can be manually operated by pressing the door up X010 (X10) and door down X011 (X11)
buttons but can function if the car is in the sensitive range.
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2. Stage Settings
Control objective: Control stage settings according to the control specifications
Circuit operation: When begin X014 (X14) is pressed on the operation panel, the normally open
contact closes causing the buzzer Y005 (Y5) to sound for 5 seconds. After 5 seconds, the relay
coil of the curtain open command Y000 (Y0) is turned ON and the curtains move positions left
X002 (X2) and right X005 (X5) respectively. After the curtains are opened, the relay coil of the
stage up command is energized and the stage moves up. The relay coil of curtain close
command Y001 (Y1) energizes when the end X017 (X17) button is pressed. This means that the
curtains positions move inside left X000 (X0) and right X003 (X3) after the normally open contact
is closed.
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3. Part Distribution
Control objective: Distribute the specified number of parts according to the size
Circuit operation: When PB1 is pressed on the operation panel, the relay coil Y000 (Y0) supplies
the command for the robot arm to transport the part onto the conveyor Y001 (Y1). The
conveyor moves forward to the right when the SW1 is pressed. The level sensors X001 (X1) for
upper, X002 (X2) for middle and X003 (X3) for lower detects the size of the part and transports
the parts along the correct conveyor Y002 (Y2), Y003 (Y3) and Y004 (Y6). As they pass through
the conveyor the 3 different normally open contacts of detect part sensors X010 (X10) for small,
X011 (X11) for medium and X012 (X12) for large senses the part size and their respective
pushers Y005 (Y5), Y006 (Y6) and Y007 (Y7) pushes them to distribute in the appropriate trays.
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4. Sorting Defective Parts
Control objective: Distinguish between defective parts and good parts by their signals
Circuit operation: When PB1 is pressed on the operation panel, it supplies the command for the
relay coil Y000 (Y0) to supply a part onto the conveyor. The conveyor Y001 (Y1) moves forward
to the right when SW1 is turned ON. The conveyor stops as soon the sensor for part under drill
X001 (X1) detects a part. This energizes the relay coil to start drilling the part. Before the parts
are distributed to the defective and ok tray, the parts are firstly detected by the detect part
sensor X010 (X10) and are either pushed by the pusher Y005 (Y5) for a defective part or moved
by the conveyor into the ok tray.
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5. Forward/Reverse Rotation Control
Control objective: Move the conveyor forward or backward according to the defected size
Circuit operation: When PB1 is pressed on the operation panel, the normally open contact of
X020 (X20) energizes the relay coil Y000 (Y0) to supply the command for the part onto the
conveyor Y001 (Y1). At the press of SW1, the conveyor turns ON by moving forward to the right.
The level sensor X002 (X2) for lower, X001 (X1) for middle and X000 (X0) for upper detects the
size of the part and the pusher Y003 (Y3) pushes the part to the designated tray. For the
medium tray, the part is lifted by the robot arm after detected by the sensor X010 (X10).
Whereas for the small and large tray, the relay coil Y003 (Y3) pushes the small and large sized
part onto the Y002 (Y2) conveyor. From there, the sensor X011 (X11) for small part and X012
(X12) for large part are distributed correctly to their respective trays with the help of their relay
coils Y005 (Y5) to move forward and YOO6 (Y6) to move in reverse.
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6. Lifter Control
Control objective: Carry parts to three positions using the lift
Circuit operation: When PB1 is pressed, the supply command of the relay coil Y000 (Y0) is
energized causing a part to be transferred onto the conveyor Y001 (Y1). After passing through
the level sensors X002 (X2) for lower, X001 (X1) for middle and X000 (X0) for upper it notifies the
relay coil of the lift up command Y002 (Y2) carry the parts to their correct conveyor positions. As
soon as the sensors X010 (X10), X012 (X12) and X014 (X14) detect the part, their respective
conveyors move forward to the right and into their designated trays. The lift conveyors stop
when the part has passed by the sensors X011 (X11), X013 (X13) and X015 (X15).
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7. Sorting and Distribution Line
Control objective: Sort each part to the specified place according to the size
Circuit operation: When PB1 is pressed, the relay coil Y000 (Y0) supplies command for the robot
arm to lift and transport a box onto the conveyor Y001 (Y1). The box passes through sensors
X001 (X1) for lower, X002 (X2) for middle and X001 (X1) for upper and notifies the relay coil for
the sorting wing Y003 (Y3) either to open or close in order for the box to continue its journey on
the conveyor Y002 (Y2). The small box is detected by the sensor X006 (X6) and pushed YOO6
(Y6) by the pusher into the tray. The large box is carried by the conveyor and dropped at the
rear end after the sensor X004 (X4) whilst the medium box is carried along the conveyor Y005
(Y5) forward towards the right and is lifted and dropt by the robotic arm in the front.
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