Single tank level controlling using PLC using FBD language

Single tank level controlling using PLC-FBD

 

This is PLC Program for single tank level controlling.

 

Problem Description:-

We need to control the level of water in the tank. Control the water level by simple PLC logic. Write the FBD diagram logic for this application.

Problem Diagram

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Problem Solution

To solve this this example we are using PLC programming. Here we have a tendency to use 2 sensors for level measurement, one is for prime level and second is for low level.

We use feeding valve for feeding Cycle for the tank and discharge valve for discharging cycle for the tank. Each valve are controlled by sensors. So once the water level goes below low level then feeding valve can activate mechanically and water level senses the high level then discharging method are activate mechanically.

Program

Here is PLC program for single tank level controlling using PLC.

List of inputs/outputs

Digital inputs:-

Main switch:-I1.1

Start button:-I0.0

Stop button:-I0.1

High level:-I0.2

Low level:-I0.3

Feeding valve:-Q0.1

Discharge valve:-Q0.2

 

Digital outputs:-

Master coil:-Q0.0

Feeding valve:-Q0.1

Discharge valve:-Q0.2

Mixer motor:-Q0.3

FBD diagram for single tank level controlling.

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Program Description

In network 1 we tend to used latching circuit for master coil ON (Q0.0) output.it will be started by pressing START Push button (I0.0) and stop by pressing STOP pushbutton (I0.1).

When cycle are going to be begin then system check level of the tank. If tank level is low then then feeding method can begin and tank level is high then Discharge cycle can begin.

Here we've taken NO contact for each sensors within the program for simplicity. It will be done by relay logic in field otherwise you will choose such variety of sensors.

In network 2,when tank can observe low level then low level sensor (I0.2) is going to be activated and feeding cycle are going to be ON. Here we've taken NC contact of high level sensor (I0.3) therefore once PLC can observe high level then it'll STOP feeding cycle.

In network 3,when tank can observe high level then high level sensor (I0.3)  is  to be activated and discharging cycle are going to be ON. Here we've taken NC contact of low level sensor (I0.2) therefore once PLC can observe low level then it'll STOP discharge cycle.

In network 4, mixer motor (Q0.3) will remain ON when discharge valve is ON.

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.

 

 

Single tank level controlling using PLC using ladder language

Single tank level controlling using PLC.

 

This is PLC Program for single tank level controlling.

 

Problem Description:-

We need to control the level of water in the tank. Control the water level by simple PLC logic. Write the ladder diagram logic for this application.

Problem Diagram

https://plcscadaacademy.blogspot.com/

Problem Solution

To solve this this example we are using PLC programming. Here we have a tendency to use 2 sensors for level measurement, one is for prime level and second is for low level.

We use feeding valve for feeding Cycle for the tank and discharge valve for discharging cycle for the tank. Each valve are controlled by sensors. So once the water level goes below low level then feeding valve can activate mechanically and water level senses the high level then discharging method are activate mechanically.

Program

Here is PLC program for single tank level controlling using PLC.

List of inputs/outputs

Digital inputs:-

Main switch:-I1.1

Start button:-I0.0

Stop button:-I0.1

High level:-I0.2

Low level:-I0.3

Feeding valve:-Q0.1

Discharge valve:-Q0.2

 

Digital outputs:-

Master coil:-Q0.0

Feeding valve:-Q0.1

Discharge valve:-Q0.2

Mixer motor:-Q0.3

 Ladder diagram for single tank level controlling.

https://plcscadaacademy.blogspot.com/

https://plcscadaacademy.blogspot.com/

https://plcscadaacademy.blogspot.com/

https://plcscadaacademy.blogspot.com/

Program Description

In network 1 we tend to used latching circuit for master coil ON (Q0.0) output.it will be started by pressing START Push button (I0.0) and stop by pressing STOP pushbutton (I0.1).

When cycle are going to be begin then system check level of the tank. If tank level is low then then feeding method can begin and tank level is high then Discharge cycle can begin.

Here we've taken NO contact for each sensors within the program for simplicity. It will be done by relay logic in field otherwise you will choose such variety of sensors.

In network 2,when tank can observe low level then low level sensor (I0.2) is going to be activated and feeding cycle are going to be ON. Here we've taken NC contact of high level sensor (I0.3) therefore once PLC can observe high level then it'll STOP feeding cycle.

In network 3,when tank can observe high level then high level sensor (I0.3)  is  to be activated and discharging cycle are going to be ON. Here we've taken NC contact of low level sensor (I0.2) therefore once PLC can observe low level then it'll STOP discharge cycle.

In network 4, mixer motor (Q0.3) will remain ON when discharge valve is ON.

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

Operating a Double-Acting Pneumatic Cylinder with START and STOP Push Buttons (Close Priority)

Operating a Double-Acting Pneumatic Cylinder with START and STOP Push Buttons (Close Priority)

Introduction

A double-acting pneumatic cylinder operates using compressed air for both extension and retraction. In this setup, we use START and STOP push buttons to control the movement of the cylinder, with a close priority system. This means that if both buttons are pressed simultaneously, the STOP button takes precedence, ensuring the cylinder retracts for safety and control.

This article covers the working principle, components, pneumatic circuit design, and AutoSIM 200 simulation of this system.

Working Principle

• START Push Button (NO - Normally Open): Activates the cylinder extension when pressed.
• STOP Push Button (NC - Normally Closed): Deactivates extension and forces retraction when pressed.
• Close Priority Logic: The STOP button overrides the START button, ensuring the cylinder retracts when both buttons are pressed at the same time.

Applications

 Safety-critical automation processes
Emergency stop mechanisms
Industrial assembly and material handling
Pressing and clamping operations

Components Required

1. Double-Acting Cylinder – Performs bidirectional movement.
2. 5/2-Way Double Pilot Valve – Controls air supply for extension and retraction.
3. START Push Button (3/2-Way NO Valve) – Sends air to the extension side.
4. STOP Push Button (3/2-Way NC Valve) – Sends air to the retraction side.
5. Air Compressor – Provides compressed air.
6. Flow Control Valves (Optional) – Controls the speed of movement.
7. Air Tubing and Fittings – Connects the components.

Pneumatic Circuit Design

Step 1: Understanding the Valve Function

• START PB (NO - Normally Open, 3/2-Way Valve)

  • When pressed → Air flows to pilot side A of the 5/2-way valve, extending the cylinder.
  • When released → The cylinder remains extended due to the pilot signal holding the valve in position.

• STOP PB (NC - Normally Closed, 3/2-Way Valve)

  • When pressed → Sends air to pilot side B of the 5/2-way valve, retracting the cylinder.
  • When released → The cylinder remains retracted, overriding the START command.

Step 2: Circuit Working Mechanism

1. Press START Button:

   • The 3/2-way NO valve opens.
   • Air enters the pilot port A of the 5/2-way valve.
   • The cylinder extends.

2. Press STOP Button:

   • The 3/2-way NC valve opens.
   • Air enters the pilot port B of the 5/2-way valve.
   • The cylinder retracts.
   • Since STOP has priority, the cylinder remains retracted even if START is pressed.

Implementation in AutoSIM 200

To simulate this circuit 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
   • 3/2-way NO valve (START PB)
   • 3/2-way NC valve (STOP PB)
   • Air supply
3. Connect the components using air tubing.
4. Run the simulation and observe the following:
   • Press START PB → Cylinder extends.
   • Press STOP PB → Cylinder retracts.
   • If both buttons are pressed, the STOP PB takes priority.

Conclusion

Using a double-acting pneumatic cylinder with START and STOP push buttons ensures controlled movement, with the STOP button having priority for safety. This setup is commonly used in industrial automation, machine safety systems, and material handling applications.

Click here to watch video https://youtu.be/K8iEcbeOj4Y

Operating a Double-Acting Pneumatic Cylinder with a Manual Hand Lever

Introduction

A double-acting pneumatic cylinder is a commonly used actuator in industrial automation, capable of extending and retracting using compressed air. Unlike single-acting cylinders, which rely on a spring for retraction, double-acting cylinders use air pressure for both movements.

In this article, we will discuss the working principle, components, and pneumatic circuit design for operating a double-acting cylinder using a manual hand lever valve.

Working Principle of a Double-Acting Cylinder

• Two air ports: One for extension and one for retraction.
• Air pressure controls both movements, making it stronger and more reliable than a single-acting cylinder.
• It is ideal for continuous or repetitive motion applications in automation.

Applications of Double-Acting Cylinders

Lifting and lowering in material handling
Clamping and holding in machining processes
Punching and pressing in manufacturing
Robotic arm movements

Components Required

To operate a double-acting cylinder using a manual hand lever, the following components are required:

1. Double-Acting Cylinder – The actuator that moves in two directions.
2. 5/2-Way Hand Lever Valve – A manually operated directional control valve.
3. Air Compressor – Provides compressed air for operation.
4. Flow Control Valves (Optional) – Regulates the speed of movement.
5. Air Tubing and Fittings – Connects all components in the pneumatic circuit.

Pneumatic Circuit Design

Step 1: Understanding the 5/2-Way Hand Lever Valve

A 5/2-way valve has:

• 5 ports:
  • P – Air supply
  • A – Cylinder extension port
  • B – Cylinder retraction port
  • R1, R2 – Exhaust ports
• 2 positions:
  • Position 1 (Lever Left) – Air flows to port A, extending the cylinder.
  • Position 2 (Lever Right) – Air flows to port B, retracting the cylinder.

Step 2: Circuit Diagram and Working

1. When the hand lever is pushed forward:

   • The valve shifts, allowing compressed air into port A.
   • The piston extends.
   • Air from port B exits through the exhaust.

2. When the hand lever is pulled backward:

   • The valve shifts to the opposite position.
   • Air enters port B, causing the piston to retract.
   • Air from port A exits through the exhaust.

Implementation in AutoSIM 200

To simulate this circuit 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 manual hand lever valve
   • Air supply
3. Connect the components using air tubing.
4. Run the simulation and operate the hand lever to observe the cylinder’s extension and retraction.

Conclusion

A double-acting cylinder with a manual hand lever valve provides precise control for industrial applications. The 5/2-way valve allows easy switching between extension and retraction, making it ideal for mechanical control in automation systems.

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

S7-1500 Hardware Configuration Using TIA Portal V19

 Introduction

The Siemens S7-1500 series PLCs are powerful automation controllers designed for high-performance industrial applications. Configuring an S7-1500 PLC in TIA Portal V19 is an essential step in developing a structured and efficient automation system.

This article provides a step-by-step guide to configuring S7-1500 hardware, including adding a PLC, configuring I/O modules, setting up communication, and downloading the configuration to the hardware.

Step 1: Open TIA Portal V19 and Create a New Project

1. Launch TIA Portal V19.
2. Click on "Create New Project" and enter:
   • Project Name (e.g., "S7-1500_Config")
   • Path to Save the Project
   • Project Description (Optional)
3. Click "Create" to open the main project workspace.

Step 2: Adding the S7-1500 PLC to the Project

1. In Project View, navigate to "Devices & Networks".
2. Click "Add New Device".
3. Under "Controller", select "SIMATIC S7-1500".
4. Choose the specific CPU model (e.g., CPU 1511-1 PN).
5. Click "Add" to insert the selected PLC into the project.

Step 3: Configuring the PLC Hardware

1. Set Up the Rack and CPU Configuration

• The rack layout appears in the device configuration window.
• Ensure the CPU is placed in Slot 1 (default for S7-1500).

2. Adding I/O Modules

1. Click on the rack’s empty slots to add I/O modules.
2. Select the appropriate digital/analog input/output modules from the hardware catalog (e.g., SM 521 DI 16x24VDC for digital inputs).
3. Drag and drop modules into the rack slots as per the system requirements.

3. Configuring I/O Addresses

1. Select an I/O module and go to the "Properties" tab.
2. Assign input and output addresses (e.g., Q0.0, I0.0).
3. Ensure that the addresses do not overlap with other modules.

Step 4: Network Configuration and IP Address Assignment

1. Open the PLC Properties

1. Select the CPU module and go to "Properties" → "PROFINET Interface".
2. Click on "Ethernet Addresses".

2. Set the IP Address

• Assign a unique IP address to the PLC (e.g., 192.168.0.1).
• Set the Subnet Mask (e.g., 255.255.255.0).

3. Configure PROFINET or Other Communication Protocols

• If using PROFINET, ensure all connected devices (HMIs, Drives, Remote I/Os) are in the same IP range.
• If required, set up PROFIBUS or Modbus TCP communication.

Step 5: Compile and Download the Configuration

1. Click "Compile" to check for errors.
2. If no errors, click "Download to Device".
3. Choose the communication interface (e.g., PN/IE for PROFINET).
4. Click "Start Search" to find connected hardware.
5. Select the PLC and download the configuration.
6. Set the PLC to RUN mode for execution.

Step 6: Testing and Monitoring the Configuration

1. Open "Online & Diagnostics" in TIA Portal.
2. Check the status of the PLC and I/O modules.
3. Use "Force Table" to manually test inputs and outputs.
4. Monitor real-time data and diagnostics to ensure proper operation.

Conclusion

Configuring an S7-1500 PLC in TIA Portal V19 is a crucial step in industrial automation. By following this guide, you can:

Set up an S7-1500 CPU and I/O modules
Assign correct I/O addresses
Configure PROFINET communication
Download and test the configuration

This structured approach ensures efficient PLC operation and seamless communication with field devices.

Click here for video 

https://youtu.be/_ddZ2bbEYUQ

Single-Acting Pneumatic Cylinder Operation with Push Button

Introduction

A single-acting pneumatic cylinder is a commonly used actuator in automation that operates using compressed air in one direction while relying on a spring or external force for retraction. This article explains the working principle, components, and circuit design for operating a single-acting cylinder using a push button.

Working Principle of a Single-Acting Cylinder

• A single-acting cylinder has one air inlet port.
• When compressed air is supplied, the piston extends.
• When the air is released, a spring inside the cylinder retracts the piston.
• This makes it energy-efficient for applications requiring unidirectional force.

Applications of Single-Acting Cylinders

 Clamping and holding mechanisms
 Part ejection in assembly lines
 Light-duty pressing operations

Components Required

To operate a single-acting cylinder using a push button, we need the following components:

1. Single-Acting Cylinder – The actuator that moves in one direction.
2. Push Button Valve (3/2 Way Valve) – A manually operated valve that controls airflow.
3. Air Compressor – Supplies compressed air.
4. Flow Control Valve (Optional) – Regulates the speed of extension.
5. Air Tubing and Fittings – Connects the components.

Pneumatic Circuit Design

Step 1: Understanding the Valve Function

A 3/2-way push button valve has:

• 3 ports: Air Supply (P), Cylinder Port (A), and Exhaust (R).
• 2 positions:
  • Default Position: Cylinder is retracted (air is blocked, exhaust open).
  • Pressed Position: Air flows to the cylinder, causing it to extend.

Step 2: Circuit Diagram and Working

1. Initial State (Button Released):

   • The spring in the cylinder retracts the piston.
   • Air does not enter the cylinder.

2. When Push Button is Pressed:

   • The valve shifts, allowing compressed air to enter the cylinder.
   • The piston extends and performs work.

3. When Button is Released:

   • The valve returns to its normal position.
   • Air escapes through the exhaust, and the spring retracts the piston.

Implementation in AutoSIM 200

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

1. Open AutoSIM 200 and select a new project.
2. Add components from the pneumatic library:
   • Single-acting cylinder
   • 3/2-way push button valve
   • Air supply
3. Connect the components using air tubing.
4. Run the simulation and press the push button to observe the cylinder extending and retracting.

Conclusion

The single-acting pneumatic cylinder with a push button is a simple and effective automation solution. Using a 3/2-way valve, the cylinder extends when the button is pressed and retracts when released. This setup is widely used in manufacturing, assembly, and material handling applications.

Click here to watch video https://youtu.be/jeOh1sOgq1o

PLC Programming Blocks: OB, FC, FB, and DB

Introduction

Programmable Logic Controllers (PLCs) are essential in industrial automation, and their efficient programming relies on different types of program blocks. In Siemens TIA Portal (Step 7) or similar PLC software, program organization is crucial for creating structured, reusable, and efficient control logic.

In this article, we will explore the four main types of PLC program blocks used in Siemens PLC programming:

1. OB (Organization Block) – Main program execution blocks
2. FC (Function) – Reusable logic without memory retention
3. FB (Function Block) – Reusable logic with memory retention
4. DB (Data Block) – Data storage for variables

Understanding these blocks will help you write better PLC programs that are scalable, modular, and easy to maintain.

1. Organization Block (OB)

What is an OB?

• Organization Blocks (OBs) control the execution of a PLC program.
• They define the priority, scan cycle, and error handling of a PLC.
• The main cycle OB (OB1) is executed cyclically, while other OBs handle specific events.

Types of OBs

1. OB1 – Main Program Cycle

   • This is the main cyclic program execution block.
   • The PLC continuously scans OB1 as long as it is in RUN mode.
   • All logic is usually called within OB1 using FCs and FBs for modular programming.

2. OB10-OB17 – Time-Triggered OBs

   • These execute at specific time intervals.
   • Useful for timed operations, such as data logging or periodic checks.

3. OB20-OB23 – Hardware Interrupt OBs

   • Triggered by hardware interrupts like sensor inputs.
   • Used for real-time critical operations.

4. OB30-OB38 – Cyclic Interrupt OBs

   • Execute at fixed time intervals.
   • Ensure consistent execution of specific tasks.

5. OB40-OB47 – Process Alarm OBs

   • Triggered by process alarms.
   • Used for fault handling.

6. OB80-OB87 – Fault Handling OBs

   • Handle errors such as division by zero, power failure, or module faults.
   • Ensures the PLC can recover from errors gracefully.

2. Function (FC)

What is an FC?

• Functions (FCs) are reusable blocks of logic that do not retain memory after execution.
• They can take input parameters and return output values, but they do not have an internal memory.
• Best suited for calculations, math operations, and temporary logic.

Key Features of FCs

No internal memory (stateless)
Accepts input parameters and returns output parameters
Used for simple, reusable logic

Use Case for FCs

• Mathematical calculations
• Signal processing
• Data conversions

3. Function Block (FB)

What is an FB?

• Function Blocks (FBs) are similar to FCs but retain memory (stateful execution).
• Used when logic needs to store data across multiple cycles.
• They require a Data Block (DB) for memory storage.

Key Features of FBs

Have internal memory (can store values between scans)
Require an Instance Data Block (DB)

Used for complex logic, motor control, and PID control

Example: FB for Motor Control

Use Case for FBs

• Motor start/stop circuits
• PID controllers
• Alarm handling

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4. Data Block (DB)

What is a DB?

• Data Blocks (DBs) store global or instance-specific data.
• Can be used to store sensor values, setpoints, or configuration parameters.
• There are two types of DBs:
  • Global DB – Shared across multiple functions.
  • Instance DB – Used with FBs to store internal memory.

Best Practices for Using OBs, FCs, FBs, and DBs

Use OB1 only for function calls – Keep OB1 clean by calling FCs and FBs instead of writing logic directly inside it.
Use FCs for stateless logic – If the function does not need memory, use an FC to keep programs modular.
Use FBs for stateful operations – If the function needs to store past values, use an FB with an instance DB.
Organize data using DBs – Store configuration parameters in DBs to make programs easier to modify.

Conclusion

Understanding OBs, FCs, FBs, and DBs is essential for writing structured, efficient, and scalable PLC programs.

• OBs define the execution cycle and event handling.
• FCs provide reusable, stateless logic.
• FBs allow memory retention for stateful processes.
• DBs store important process data.

By using these blocks strategically, you can build flexible automation solutions that are easy to maintain and expand. 

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