Develop a program in FBD Logic in SIMATIC Manager for an automatic material mixing system using a PLC.

Automatic material mixing system using PLC (S7-300 FBD).

This is PLC Program for automatic material mixing system using PLC.

 

Problem Description:-

We need to mix two material (material 1 and material 2). Provide separate switch for each material. And also provide facility for mixed material for the same. Write FBD diagram logic for the application.

Problem Diagram:-

Problem Solution
For explanation we are able to think about straight forward example of mixing system. During this application pure unmixed material is ready by the action of SW S1 and S2.And mixed material is ready by the action of SW3.

Operator watches the extent of the tank and he will discharge tank by the discharge valve and we keep the mixer motor ON whereas tank is being filled. We are going to give interlock system thus user cannot operate each switch at same time.

Program

Here is PLC program for Automatic material mixing system using PLC.

List of inputs

SW 1:-I0.0

SW 2:-I0.1

SW 3:-I0.2

Mixer trip:-I0.3

List of outputs

Material valve 1:-Q0.0

Material valve 2:-Q0.1

Discharge valve:-Q0.2

 FBD diagram for the automatic material mixing system using PLC

Program Description

In network 1 we used NO contact of SW1 (I0.0) and NC contact of SW2 (I0.1) and NC contact of SW3 (I0.2) in series. By activating SW1 operator can START the valve for material 1

In network 2 we have taken NO contact of SW2 (I0.1) and NC contact of SW1 (I0.0) and SW3 (I0.2) in series. By activating SW2 (I0.1) operator can START the valve for material 2.

In network 3 mixer motor will START when one of the valve is running out of two valves. If there is some fault in motor then motor will not start.

 

Note:-Application is only for learning and educational purpose .Above application may be different from actual application. This application can be done in other PLC also. Users are responsible for correct operation of the PLC system and for any possible injuries and or material damages resulting from the use of this program. It is necessary to take care of safety during implementation, installation, maintenance and operation.

 All parameters and graphical representations considered in this example are for explanation purpose only, parameters or representation may be different in actual applications. Also all interlocks are not considered in the application.

 

Open-Close Pneumatic Circuit for Heavy Doors

 Open-Close Pneumatic Circuit for Heavy Doors

Introduction

In industrial and commercial settings, pneumatic systems are widely used for automated door operations. A heavy-duty door can be controlled using a double-acting pneumatic cylinder, ensuring smooth and efficient opening and closing. This system is commonly used in factory gates, automated warehouse doors, aircraft hangars, and clean rooms.

This article explains the working principle, components, pneumatic circuit design, and implementation using AutoSIM 200 for an open-close pneumatic circuit for a heavy door.

Working Principle

• A double-acting pneumatic cylinder provides bidirectional movement for opening and closing the door.
• A 5/2-way control valve directs air to either extend or retract the cylinder.
• The circuit can be controlled using:
  • Manual push buttons (for basic operation).
  • Limit switches or sensors (for automated control).
  • A solenoid valve (for integration with a PLC or remote control system).

Open Priority or Close Priority

• Open Priority: If both signals (open and close) are given simultaneously, the door remains open for safety reasons.
• Close Priority: Ensures the door closes automatically, even if the open signal is still active, used in security applications.

Applications

✔ Factory automation – Warehouse entry doors
✔ Transportation hubs – Automated train and metro doors
✔ Secure access control – High-security doors and vaults
✔ Aircraft hangars – Large doors for aircraft movement

Components Required

1. Double-Acting Pneumatic Cylinder – Provides the force to open and close the door.
2. 5/2-Way Double Solenoid Valve – Controls the airflow direction for opening and closing.
3. Push Buttons (3/2-Way NO Valves) – Start the opening and closing actions.
4. Air Compressor – Supplies compressed air to the system.
5. Flow Control Valves – Regulates the speed of door movement.
6. Proximity Sensors or Limit Switches (Optional) – Ensures precise stopping positions.
7. Air Tubing and Fittings – Connects all components.

Pneumatic Circuit Design

Step 1: Understanding the Control Valves

• 5/2-Way Double Solenoid Valve

  • Solenoid A activated → Air enters the extension port, opening the door.
  • Solenoid B activated → Air enters the retraction port, closing the door.

• Push Button (NO - Normally Open, 3/2-Way Valve)

  • One button sends an open signal to solenoid A.
  • Another button sends a close signal to solenoid B.

• Limit Switches (Optional)

  • One at the fully open position to deactivate solenoid A.
  • One at the fully closed position to deactivate solenoid B.

Step 2: Circuit Working Mechanism

1. Press "Open" Push Button

   • Activates solenoid A on the 5/2-way valve.
   • Air enters the extension port, causing the cylinder to extend and open the door.
   • When the door reaches the fully open position, a limit switch stops the movement.

2. Press "Close" Push Button

   • Activates solenoid B on the 5/2-way valve.
   • Air enters the retraction port, causing the cylinder to retract and close the door.
   • When the door is fully closed, a limit switch stops the movement.

3. If Automated Sensors Are Used

   • A motion sensor can detect presence and automatically open the door.
   • A time delay can trigger the door to close after a few seconds.

Implementation in AutoSIM 200

To simulate this system in AutoSIM 200, follow these steps:

1. Open AutoSIM 200 and create a new project.
2. Add components from the pneumatic library:
   • Double-acting cylinder
   • 5/2-way double solenoid valve
   • Two 3/2-way NO push buttons (Open/Close buttons)
   • Limit switches (optional)
   • Air supply
3. Connect the components using air tubing.
4. Run the simulation and observe:
   • Press Open button → Cylinder extends, door opens.
   • Press Close button → Cylinder retracts, door closes.
   • If limit switches are used, they automatically stop movement at open/closed positions.

Conclusion

Using a double-acting pneumatic cylinder and a 5/2-way valve, a heavy-duty pneumatic door can be efficiently controlled. The open-close mechanism can be manually operated using push buttons or automated using sensors and PLC control.

Click here to watch video           https://youtu.be/TA3_krqiZOo

Develop a program in Ladder Logic in SIMATIC Manager for an automatic material mixing system using a PLC

Automatic material mixing system using PLC (S7-300 LAD).

 

This is PLC Program for automatic material mixing system using PLC.

 

Problem Description:-

We need to mix two material (material 1 and material 2). Provide separate switch for each material. And also provide facility for mixed material for the same. Write ladder diagram logic for the application.

 

Problem Diagram

Problem Solution
For explanation we are able to think about straight forward example of mixing system. During this application pure unmixed material is ready by the action of SW S1 and S2.And mixed material is ready by the action of SW3.

Operator watches the extent of the tank and he will discharge tank by the discharge valve and we keep the mixer motor ON whereas tank is being filled. We are going to give interlock system thus user cannot operate each switch at same time.

Program

Here is PLC program for Automatic material mixing system using PLC.

List of inputs

SW 1:-I0.0

SW 2:-I0.1

SW 3:-I0.2

Mixer trip:-I0.3

List of outputs

Material valve 1:-Q0.0

Material valve 2:-Q0.1

Discharge valve:-Q0.2

 

Ladder diagram for the automatic material mixing system using PLC (S7-300 LAD).

Program Description

In network 1 we used NO contact of SW1 (I0.0) and NC contact of SW2 (I0.1) and NC contact of SW3 (I0.2) in series. By activating SW1 operator can START the valve for material 1

In network 2 we have taken NO contact of SW2 (I0.1) and NC contact of SW1 (I0.0) and SW3 (I0.2) in series. By activating SW2 (I0.1) operator can START the valve for material 2.

In network 3 mixer motor will START when one of the valve is running out of two valves. If there is some fault in motor then motor will not start.

 Note:-Application is only for learning and educational purpose .Above application may be different from actual application. This application can be done in other PLC also. Users are responsible for correct operation of the PLC system and for any possible injuries and or material damages resulting from the use of this program. It is necessary to take care of safety during implementation, installation, maintenance and operation.

All parameters and graphical representations considered in this example are for explanation purpose only, parameters or representation may be different in actual applications. Also all interlocks are not considered in the application.

Automatic material mixing system using FBD Programming language

Automatic material mixing system using PLC(S7-1200 FBD).

 

This is PLC Program for automatic material mixing system using PLC.

 

Problem Description:-

We need to mix two material (material 1 and material 2). Provide separate switch for each material. And also provide facility for mixed material for the same. Write FBD diagram logic for the application.

 

Problem Diagram

Problem Solution

For explanation we are able to think about straight forward example of mixing system. During this application pure unmixed material is ready by the action of SW S1 and S2.And mixed material is ready by the action of SW3.

Operator watches the extent of the tank and he will discharge tank by the discharge valve and we keep the mixer motor ON whereas tank is being filled. We are going to give interlock system thus user cannot operate each switch at same time.

Program

Here is PLC program for Automatic material mixing system using PLC.

List of inputs

SW 1:-I0.0

SW 2:-I0.1

SW 3:-I0.2

Mixer trip:-I0.3

List of outputs

Material valve 1:-Q0.0

Material valve 2:-Q0.1

Discharge valve:-Q0.2

 

FBD diagram for the automatic material mixing system using PLC

Program Description:- 

In network 1 we used NO contact of SW1 (I0.0) and NC contact of SW2 (I0.1) and NC contact of SW3 (I0.2) in series. By activating SW1 operator can START the valve for material 1

In network 2 we have taken NO contact of SW2 (I0.1) and NC contact of SW1 (I0.0) and SW3 (I0.2) in series. By activating SW2 (I0.1) operator can START the valve for material 2.

In network 3 mixer motor will START when one of the valve is running out of two valves. If there is some fault in motor then motor will not start.

Note:-Application is only for learning and educational purpose .Above application may be different from actual application. This application can be done in other PLC also. Users are responsible for correct operation of the PLC system and for any possible injuries and or material damages resulting from the use of this program. It is necessary to take care of safety during implementation, installation, maintenance and operation.

 All parameters and graphical representations considered in this example are for explanation purpose only, parameters or representation may be different in actual applications. Also all interlocks are not considered in the application.

Automatic material mixing system using PLC using Ladder Language

Automatic material mixing system using PLC.

 

This is PLC Program for automatic material mixing system using PLC.

 

Problem Description:-

We need to mix two material (material 1 and material 2). Provide separate switch for each material. And also provide facility for mixed material for the same. Write ladder diagram logic for the application.

Problem Diagram

Problem Solution

For explanation we are able to think about straight forward example of mixing system. During this application pure unmixed material is ready by the action of SW S1 and S2.And mixed material is ready by the action of SW3.

Operator watches the extent of the tank and he will discharge tank by the discharge valve and we keep the mixer motor ON whereas tank is being filled. We are going to give interlock system thus user cannot operate each switch at same time.

Program

Here is PLC program for Automatic material mixing system using PLC.

List of inputs

SW 1:-I0.0

SW 2:-I0.1

SW 3:-I0.2

Mixer trip:-I0.3

List of outputs

Material valve 1:-Q0.0

Material valve 2:-Q0.1

Discharge valve:-Q0.2

 Ladder diagram for the automatic material mixing system using PLC

Program Description

In network 1 we used NO contact of SW1 (I0.0) and NC contact of SW2 (I0.1) and NC contact of SW3 (I0.2) in series. By activating SW1 operator can START the valve for material 1

In network 2 we have taken NO contact of SW2 (I0.1) and NC contact of SW1 (I0.0) and SW3 (I0.2) in series. By activating SW2 (I0.1) operator can START the valve for material 2.

In network 3 mixer motor will START when one of the valve is running out of two valves. If there is some fault in motor then motor will not start.

Note:-Application is only for learning and educational purpose .Above application may be different from actual application. This application can be done in other PLC also. Users are responsible for correct operation of the PLC system and for any possible injuries and or material damages resulting from the use of this program. It is necessary to take care of safety during implementation, installation, maintenance and operation.

 All parameters and graphical representations considered in this example are for explanation purpose only, parameters or representation may be different in actual applications. Also all interlocks are not considered in the application.

OR Valve and Series Connection in Pneumatic Circuit

In pneumatic control systems, an OR valve is a crucial component that allows alternative flow paths for air, enabling a flexible operation of devices. The series connection of pneumatic components refers to the way components are connected in a series to perform specific sequential actions.

This article explores the OR valve and its use in a series connection within a pneumatic circuit, covering the working principles, components, and circuit designs.

What is an OR Valve?

An OR valve is a type of pneumatic valve used to create alternative flow paths. It is typically a 3/2-way valve that allows air to flow to one of two outputs based on which input is activated.

The key function of an OR valve is to select one of the available paths for airflow based on external signals. This makes it useful in circuits where different actions can be triggered by either of two inputs.

Key Characteristics of OR Valves

• 3/2-Way OR Valve: The valve has three ports and two positions, and the flow can be directed to one of the outputs depending on the active input.
• Control Flexibility: Allows for the combination of multiple inputs to control the same output.
• Safety: Prevents system overload by managing the airflow paths effectively.

Working Principle of OR Valve in Pneumatic Circuit

An OR valve can be connected to either a push button or a limit switch. It ensures that air flows to the output from either of the input sources based on which is activated.

Here’s how it works:

• Input 1 Activated: Air is directed to the output through port A.
• Input 2 Activated: Air is directed to the output through port B.
• If both inputs are activated, either path can be used, ensuring flexibility in system operation.

The OR valve is often used when you need to provide an alternative air path or for redundancy purposes. For example, in a cylinder actuation system, two sensors or buttons can trigger the same operation, but each has its own independent signal.

Series Connection in Pneumatic Circuit

In a series connection setup, pneumatic components (such as cylinders, valves, or limit switches) are connected one after the other, forming a sequence of operations. This method ensures that the pneumatic system operates in a controlled order, with each component activated sequentially based on the condition of the previous one.

How Does Series Connection Work?

• Series Operation: Components in the series will operate only when the previous component is activated. For example, if multiple limit switches are connected in series, the cylinder will only extend if all limit switches are activated in sequence.
• Sequential Control: If there is a failure or deactivation in one of the components, the entire series will be halted.
• Common Applications: Safety systems, sequential material handling, and process automation, where conditions must be met in a specific order.

Combining OR Valve and Series Connection in Pneumatic Circuit

When combining OR valves and series connections, you create a circuit that offers flexibility and control. The OR valve ensures multiple input sources can trigger the same output, while the series connection ensures that components must be activated in a specific order.

Example: Cylinder Control Using OR Valve and Series Connection

In a system where a double-acting cylinder is used, the OR valve can be employed to allow either of two buttons (or sensors) to extend the cylinder. A limit switch could be connected in series to ensure the cylinder retracts only when the right conditions are met.

1. Step 1: Press Button 1 (or Trigger Sensor 1)

   • The OR valve directs air to the cylinder extension port, causing the cylinder to extend.

2. Step 2: Press Button 2 (or Trigger Sensor 2)

   • Air is directed through the OR valve and reaches the cylinder, causing it to extend even if Button 1 wasn’t pressed.

3. Step 3: Limit Switch in Series for Retraction

   • Once the cylinder has fully extended, the limit switch in the series path activates and sends a signal to the valve to retract the cylinder.

By combining the OR valve with a series connection of components, the system becomes more adaptable, and the overall control is optimized for both flexibility and safety.

Advantages of Using OR Valve and Series Connection

• Flexibility: The OR valve allows multiple inputs to control the same output, making it adaptable for different operational conditions.
• Redundancy: If one input fails, the alternative input can still activate the output.
• Sequence Control: The series connection ensures the system operates in the correct sequence, which is critical for applications that require strict control.
• Simplicity in Design: By combining an OR valve with a series connection, you can achieve complex functionality with minimal components.

Implementation in AutoSIM 200

To simulate this system in AutoSIM 200, follow these steps:

1. Open AutoSIM 200 and create a new project.
2. Add components from the pneumatic library:
   • OR valve (3/2-way valve)
   • Double-acting cylinder
   • Limit switches
   • Push buttons or sensors
3. Connect the components in series, ensuring the OR valve is correctly wired to the push buttons and sensors.
4. Run the simulation and test the circuit:
   • Activate one input → Cylinder extends.
   • Activate both inputs → Cylinder still extends.
   • Limit switches in series will control the cylinder’s retraction.

Conclusion

The OR valve and series connection in a pneumatic circuit offer a flexible, reliable, and cost-effective solution for controlling complex pneumatic systems. By combining the OR valve’s alternative flow path with the series connection’s sequential control, you can design circuits that provide efficient operation for a variety of automation tasks.

Click here for video   https://youtu.be/j8nt_lDCvfY

Pneumatic Circuit for Feeding Action Using a Push Button

 Introduction

In many industrial automation systems, feeding mechanisms are used to move materials or components into a machine. A pneumatic feeding system can be controlled using a push button, which activates a double-acting pneumatic cylinder to push the material forward.

This article explains the working principle, components, circuit design, and simulation using AutoSIM 200 for a pneumatic feeding system controlled by a push button.

Working Principle

• A push button (3/2-way normally open valve) is used to initiate the feeding action.
• When the push button is pressed, compressed air extends the double-acting cylinder, moving the material forward.
• When the button is released, the cylinder automatically retracts, preparing for the next cycle.

Applications

✔ Assembly lines – Feeding components into machines
✔ Conveyors – Pushing materials forward in production lines
✔ Packaging machines – Moving products for sealing or labeling
✔ Pressing machines – Feeding metal sheets for stamping

Components Required

1. Double-Acting Cylinder – Pushes the material forward.
2. 3/2-Way Normally Open Push Button Valve – Activates the feeding action.
3. 5/2-Way Single Solenoid Valve (Spring Return) – Controls cylinder extension and retraction.
4. Air Compressor – Supplies compressed air.
5. Flow Control Valves – Adjusts the speed of cylinder movement.
6. Air Tubing and Fittings – Connects all components.

Pneumatic Circuit Design

Step 1: Understanding the Valve Function

• 3/2-Way Push Button Valve (NO)

  • Default: Air is blocked, cylinder is retracted.
  • Pressed: Air flows to solenoid valve, causing the cylinder to extend.

• 5/2-Way Single Solenoid Valve with Spring Return

  • When energized (receiving air from the push button), it extends the cylinder.
  • When the push button is released, the solenoid deactivates, and the spring return retracts the cylinder.

Step 2: Circuit Operation

1. Press Push Button

   • Air flows to the 5/2-way solenoid valve.
   • The valve shifts, allowing air to enter the cylinder’s extension port.
   • The cylinder extends, pushing the material forward.

2. Release Push Button

   • The solenoid deactivates, and the spring return shifts the valve back.
   • Air exhausts from the extension side, and new air enters the retraction port.
   • The cylinder retracts to its initial position, ready for the next cycle.

Implementation in AutoSIM 200

To simulate this system in AutoSIM 200, follow these steps:

1. Open AutoSIM 200 and create a new project.
2. Add components from the pneumatic library:
   • Double-acting cylinder
   • 3/2-way NO push button valve
   • 5/2-way solenoid valve (spring return)
   • Air supply
3. Connect the components using air tubing.
4. Run the simulation and test the operation:
   • Press the push button → Cylinder extends (feeding action).
   • Release the push button → Cylinder retracts (reset position).

Conclusion

Using a push button to initiate a feeding action with a double-acting cylinder provides a simple and effective automation solution. The spring-return mechanism ensures the system resets automatically, making it ideal for material handling, packaging, and assembly processes.

Click here to watch video https://youtu.be/PiMe5aYDPAM

Series Connection of Pneumatic Limit Switches to Operate a Double-Acting Cylinder

Introduction

Pneumatic limit switches are commonly used in automation systems to control the movement of pneumatic cylinders. By connecting these switches in series, we can create a sequential control system where a double-acting cylinder operates only when all required conditions are met.

This article explains the working principle, components, pneumatic circuit design, and implementation using AutoSIM 200 for a series connection of pneumatic limit switches to operate a double-acting cylinder.

Working Principle

• A double-acting cylinder is used to perform bidirectional movement.
• Two pneumatic limit switches are placed in series to control the extension and retraction of the cylinder.
• The cylinder will extend only when both limit switches are activated.
• If either switch is not activated, the cylinder remains in its current position.

Applications

Sequential control systems – Ensures process safety
Workpiece detection systems – Operates only when conditions are met
Safety interlocks – Prevents unintended cylinder movement
Material handling – Ensures objects are properly positioned before operation

Components Required

1. Double-Acting Pneumatic Cylinder – Moves in both directions.
2. 5/2-Way Double Pilot Valve – Controls airflow for extension and retraction.
3. Two Pneumatic Limit Switches (3/2-Way NC Valves) – Detects position and controls air supply.
4. Air Compressor – Provides compressed air.
5. Flow Control Valves – Adjusts cylinder movement speed.
6. Air Tubing and Fittings – Connects components.

Pneumatic Circuit Design

Step 1: Understanding the Limit Switches

• Pneumatic Limit Switches (3/2-Way Normally Closed Valves)
  • When both switches are activated, air flows to the 5/2-way valve, extending the cylinder.
  • If either switch is deactivated, airflow is blocked, stopping the cylinder.

Step 2: Circuit Operation

1. Both Limit Switches Activated

   • Air flows through both switches to the pilot port A of the 5/2-way valve.
   • The valve shifts, directing air to the cylinder extension port.
   • The cylinder extends.

2. Either Switch Released

   • Air supply to the 5/2-way valve is interrupted.
   • The valve returns to its neutral state, and the cylinder remains in its last position.

3. Retraction of the Cylinder

   • When both switches are released, air flows to pilot port B of the 5/2-way valve, retracting the cylinder.

Implementation in AutoSIM 200

To simulate this system in AutoSIM 200, follow these steps:

1. Open AutoSIM 200 and create a new project.
2. Add components from the pneumatic library:
   • Double-acting cylinder
   • 5/2-way double pilot valve
   • Two 3/2-way NC pneumatic limit switches
   • Air supply
3. Connect the components using air tubing.
4. Run the simulation and test the system:
   • Activate both limit switches → Cylinder extends.
   • Deactivate either switch → Cylinder stops or retracts.

Conclusion

By using pneumatic limit switches in series, we ensure that a double-acting cylinder only operates when all required conditions are met. This method is widely used in safety systems, material handling, and sequential control applications.

Click here to watch  https://youtu.be/6_4mYoA6I3A