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.