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PB1130 Digital technology - Project

2023 H, Porsgrunn

In this project you have to work with the three systems listed below:

1. "Two-out-of-three" system with function table and alarm (see pages 2-4)
2. Silo filling with power control (see page 5)
3. Control of bending test with LOGO!Soft PLC (see page 6-11)

Aim of the assignment:

• Create a PLC program (using LOGO!Soft) based on a given requirement specification. • Make the bend tester
work as intended. • Demonstrate the work that has been
done to get the project approved.

About the project report to be delivered:

As a deliverable, your group must submit a short group report (approx. 5-10 pages) which should include:

• Name and group number. ALL name of the group members and group number • Show the process of
how you designed a logic circuit based on a given requirement specification. • Screenshot of the program with a
description of how the program works • Conclusion • Attachments if any

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1. "Two-of-Three" System with Function Table and Alarm

In this assignment, we will look a little at the monitoring of alarm limits in a process.

When a quantity reaches its maximum value in a system, be it the upper level in a tank, maximum permissible
pressure in a pressure tank or maximum permissible temperature in a reaction tank, one wants to detect this value
so that a signal from the system can give a warning to the operator who must then ensure that the necessary
operations are carried out to avoid further escalation.

The sensor that signals that the alarm limit has been reached can be a simple detector, but if the part of the process
the alarm is in is very important, there will often be three detectors on the same signal to increase safety. These can
be set to the same limit value or what is most common is that they are set with a small deviation from each other. When
you do it this way, the alarm signal can be just one of several signals you get from this sensor group,
namely: Pre-alarm, Interlock, Alarm and Error message.

Figure 1 Open tank with three level detectors: L1, L2 and L3

The part of the process we will look at in this task is the level in an open tank. This must not exceed a certain value, and
we have therefore placed three level detectors L1, L2 and L3 as sensors for this value.
These detectors are such that they give the signal "0" when they are not covered with liquid, and "1" when the liquid
covers them. They are set up at slightly different heights as Figure 1 shows.

1.1 Process description

The monitoring system will work as follows as the water level rises:

1. Pre-alarm, FA, is given by means of a fixed light lamp as soon as L1 is covered with liquid.
2. The interlock signal, NH, is activated when at least two of the three sensors are activated, regardless
which ones.

This signal is used as a message to any control system that the limit value has been reached. This is done
to reduce the probability that NH will not be activated when it should due to a fault on one of the sensors.
This is how we will also think of the system in this assignment.
3. The main alarm, A, is given when all the sensors are covered with liquid. (This alarm is displayed in a specific
way which we will return to, see 1.2 Alarm).
4. As an additional function, you often have a lamp, F, which lights up if there is a fault with one of the switches
the sensors.

When we set this up in a function table with the three inputs L1, L2 and L3 and the outputs FA, NH, A and F, we get a
result that Table 1 gives us.

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Table 1 Function table (truth table)

L1 L2 L3 FEW NH A F
0 0 0 0 0 0 0
0 0 1 0 0 0 1
0 1 0 0 0 0 1
0 1 1 0 1 0 1
1 0 0 1 0 0 0
1 0 1 1 1 0 1
1 1 0 1 1 0 0
1 1 1 1 1 1 0

1.2 Alarm
The lamp, LA, used to indicate alarm has three functional areas:

Lamp, LA 1 Functional areas

Dark lamp 2 Flashing Normal condition. No alarm.
lamp (flashing at 2 Hz) Alarm condition. First phase in case of alarm.
3 Steady light lamp Acknowledged alarm.

The operator has seen the alarm and acknowledged it with a push button.

The cause of the alarm has not been removed.

If the cause of the alarm disappears in position 2 or 3, the system switches to normal state, dark lamp, immediately.

Hint:
• The logic circuit that performs this alarm function must contain a flip-flop and a clock pulse generator (KP-gen), and can
e.g. look like in Figure 2 below. ("Kv": the button is for Acknowledged alarm)

Figure 2 Logic circuit for alarm function

• Use the "Asynchronous pulse generator" block to generate the

KP signal. You can find this block under Special Functions/ Timer.
Under "Properties" you can set the flashing frequency.

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1.3 Task I (1, 2 and 3)

1. Design a logic circuit based on a given requirement specification using sensors L1, L2, L3
as inputs and FA, NH, A, F and LA as outputs.
2. Use LOGO!Soft to program and test that the function of the system is as desired by
simulate inputs and outputs. Screenshots of simulation results with descriptions should be included in the report.

3. Draw a timing diagram showing the connection between inputs and outputs for a normal
ALARM cycle:
Normal --> Pre-alarm --> Interlock signal --> Alarm occurs --> Alarm not acknowledged -->
Alarm acknowledged --> (Normal)

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2. SILO FILLING WITH EFFECT CONTROL

We imagine three silos A, B and C to be filled from a separate pump, see Figure 3. A detector for low level, ,
and one for high level, when the liquid level is higher than the (= , , ). These give the signal "1"
detector, is mounted on each silo.

Figure 3 Silo A, B and C

2.1 Process description

The electric pumps PA, PB and PC must be controlled so that they:

• Always runs when the level, , in the respective silo is lower than ,(<)
• Never runs when the level, , is higher than , ( > )
• Power is controlled when the level, , is between and , ( H ÿ ÿ L), so that the supply is utilized
maximum, but not overloaded, unless one of the preceding conditions requires it.
Overloading is therefore permitted when the pumps MUST run, due to too low level as < . If there is
freedom of choice, the largest pump shall be given priority.
• The pumps respectively use: PA = 1 kW, PB = 3 kW and PC = 5 kW. Overload occurs
when total power consumption, , ice ÿ 7 kW.

2.2 Task II (1 and 2)

1. Set up a function table for the three outputs PA, PB and PC. When you set up these tables, you should take
into account that not all combinations are possible if you assume a flawless system. In that case, you should
create a separate output, F, which indicates that a fault has occurred at the detectors in one of the silos.
Remember the priorities.
2. Use LOGO!Soft to program and test that the function of the system is as desired by
simulate inputs and outputs. Screenshots of simulation results with descriptions should be included in the
report.

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3. Project: Control of Bending Testers with LOGO!Soft PLC

3.1 Process description
Figure 4 is the picture of the bending machine that we will use in this project.

Figure 4 Image of bending test.

Solar panels consist of thin discs made of silicon. These discs (or wafers) are fragile and as part of quality control
they are subjected to mechanical stress in a bend tester, as an example shown in Figure 5.

Figure 5. Production of silicon wafers.

Source: https:// www.pv-tech.org/ news/ rec-solar-to-expand-production-and-rd-investment-in-singapore

The bend tester deforms the wafers in two directions using two sets of eccentric wheels (see Figure 6) which are set
in rotation by each cylinder, S1 or S2 (see Figure 7) when a wafer passes the photocell, LS1 or LS2 (see Figure 8) .
The wafers are passed through the tester using the motor M1 (see Figure 9). A control panel with a Start/stop button
(toggle) and a button for simulating wrecks is connected to the bend tester (see Figure 10)

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Figure 6 Eccentric wheels that apply mechanical stress to the wafers

Figure 7 Cylinders S1 and S2 which set the eccentric wheels in motion

Figure 8 Photocells LS1 and LS2 which detect that a wafer is approaching the stress test area

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Figure 9 Motor M1 which guides the wafers through the tester

Figure 10 Control desk with start/ stop button and button for simulating wrecks

3.2 Task III (1, 2 and 3)

1. Using the I/O list given in Table 2, create a PLC program that works as follows:
• When the Start/Stop button is pressed, motor M1 is switched on. The operator inserts the wafer. •
When the wafer is detected by LS1, cylinder S1 is pushed out and rotates the first stress
test wheel.
• When the wafer is detected by LS2, cylinder S2 is pushed out and rotates the second stress test wheel.
The wafer then continues to the collection ramp at the end of the bend tester. The bend tester is
stopped by pressing the Start/Stop button again. Hint: Use the Trigger input on the "Pulse Relay" block
to toggle the output.

Other requirements:

• If no new wafers are fed in within 5 seconds of the last stress test
completed, the bend tester must stop automatically and must be restarted by the operator.

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• The bend tester must also stop if there are too many wafers on the collection ramp. IN
in which case the operator must remove the wafers and restart the bend tester.
• It must be shown on the display of the PLC how many wafers have been produced and where
many that have been wrecked.
• It must be possible to reset the counter. • Use
the Wreck button to simulate wreckage.

Table 2 I/ O list:

Inputs (I) Outputs (O)

I1 (Not in use) Q1 Start / Stop of Motor M1

I2 (Not in use) Q2 (Not in use)

I3 Start / Stop Q3 Cylinder S1

I4 Simulation of wrecks Q4 Cylinder S2

I5 Photocell LS1
I6 Photocell LS2

Figure 11 Desired waveform of M1, LS1, LS2, S1 and S2.

Hint:
• When simulating the program, the Input blocks must
be set to act as pressure switches, as shown in
Figure 12.

Figure 12

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2. Downloading the program to the PLC on the bend tester and test Risk
analysis must be approved by the supervisors in order to test drive the tester.

Down in the right corner of the LOGO!Soft window, you will see which PLC type has been selected for the project, as
shown in Figure 13.

Figure 13 The PLC type has been selected for the project

The PLC used on the bend tester is of type 0BA6.ES10. If it says something else in your project, you must double-click
on the field where the PLC type is written and select the correct type, as shown in Figure 14.

Figure 14 Select the correct PLC type

Then go to the settings for Message Text and disable "Use new feature":

Figure 15 Deactivate the use of the new function in the Message texts setting

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The two functions marked below are used to control the display on the PLC and read the buttons at the
display:

Figure 16 Check the display on the PLC and read the buttons on the display.

When you double-click on the Message texts box in the program, you get a matrix where you can build up the
content of the display. See the example in Figure 17.

Figure 17 Build up the content of the display

3. A short description and screenshot

To include the items below in your report:

• The process of how you designed a logic circuit based on a given requirement specification.
• A brief description of how the bend tester works, designed as an operator's manual. • Screenshot
of the program with a description of how the program works

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