SESSION1: INTRODUCTION OF TIA PORTAL SOFTWARE

Software Used: TIA portal v15.1

CPU used : S7-1200 1214C DCDCDC CPU SIEMENS

Click "Read More"  For video

Please like, Share and Subscribe our YouTube Channel : A Creative - YouTube

Subscribe Our Channel : Free Subscribe!!

Small part hot plate welding.

Small part hot plate welding.

Application:-Weld two small plastic parts with the hot plate welding method. Write the PLC program for the hot plate welding process using a ladder diagram language.

Diagram:-

Explanation:-

Hot plate welding the method is a popular method for plastic part welding in the plastic industry. Generally, two parts are melted at a certain temperature and joint together in this method. We can use this method for two plastic parts welding.

 

Special Rules to design ladder diagram logic

-Signals selection, Decisions section and Actions Section

-The sequence of the logic should be left to right

NORM_X AND SCALE_X value scaling in the S7-1200 PLC

Design and implement a PLC program in Siemens S7‑1200 that processes the analog signal from the pressure transmitter, normalizes it, and scales it into engineering units (bar), ensuring accurate and reliable pressure monitoring for display and control using NORMA_X and SCALE_X

PLCSCADACADEMY

Explanation

1. Hardware Integration (S7-1200)

The S7-1200 typically features onboard analog inputs (0-10V) or uses signal boards/modules for current signals (4-20mA).

Wiring the Pressure Transmitter

• 2-Wire Transmitter: The transmitter is powered by the loop. The PLC provides 24V DC.

             Path: L+ → Transmitter (+) → Transmitter (-) → PLC Input (+) → PLC Input (-) → M.

• 4-Wire Transmitter: The transmitter has separate power and signal wires.

             Path: Signal (+) → PLC Input (+) | Signal (-) → PLC Input (-).

S7-1200 Addressing & Range

• Onboard AI: Usually %IW64 and %IW66.
• Expansion Modules: Addressing starts at %IW96 or higher.
• Digital Range: 0 to 27648 (Normal range).
• Deadband/Wire Break: For 4-20mA, if the raw value drops to -4864, it indicates 0 mA (wire break).

2. Technical Case Study: Pressure Measurement

Application: Monitoring a hydraulic line pressure.

• Sensor: 4-20 mA Pressure Transmitter.
• Physical Range: 0.0 to 100.0 Bar.
• PLC: S7-1200 with an AI 4x13 bit SM 1231 module.

Signal Mapping Table

Pressure (Bar)	Signal (mA)	S7 Raw Value (%IW)	S7 Normalized (0.0 - 1.0)
0.0 Bar	4 mA	0	0.00
25.0 Bar	8 mA	6,912	0.25
50.0 Bar	12 mA	13,824	0.50
75.0 Bar	16 mA	20,736	0.75
100.0Bar	20 mA	27,648	1.00

 

PLC program:-

Write the ladder program for the above application using ladder diagram language. Here for ladder logic, we can use any supported PLC system like S7-1200, S7-300, S7-1500, or any other PLC which can support this instruction. For PLC logic we need digital inputs and outputs.

Define the memory register for the program as per the following address,

List of M Memory

MW10:-For analog value (0 to 27648). ( Convert int to real for real value )

MW12:-Out of NORM_X ( Convert int to real for real value )

MW14:-Output value ( Convert int to real for real value )

 

PLCSCADAACADEMY

PLCSCADAACADEMY

PLC program Explanation:-

 Network 1 – Input Value Conversion (NORM_X)

• Instruction used: NORM_X
• Purpose: To normalize the raw analog input value into a floating‑point number between 0.0 and 1.0.
• Why needed:
• Analog input modules return integer values (e.g., 0 to 27648 for 0–20 mA).
• These raw values are not directly meaningful in engineering terms.
• Normalization ensures that no matter the input range, the value is scaled into a standardized ratio (0.0–1.0).

Process:

1. The PLC reads the raw analog input (e.g., 0–27648).
2. NORM_X divides the input by the maximum possible value.

3. Result is always between 0.0 (minimum) and 1.0 (maximum).

Example:

• Raw input = 13,824 (half of 27,648)
• Normalized value = 0.5

So, the sensor signal is now expressed as a percentage of full scale.

Network 2 – Output Value Conversion (SCALE_X)

• Instruction used: SCALE_X
• Purpose: To convert the normalized value (0.0–1.0) into a desired engineering unit range.
• Why needed:
• Engineers want values in real units (temperature, pressure, speed, etc.).
• SCALE_X maps the normalized ratio into the chosen engineering range.

Process:

1. Take the normalized value from Network 1.
2. Multiply it by the engineering unit span (Max – Min).
3. Add the minimum engineering unit value.

Example:

• Normalized value = 0.5
• Engineering unit range = 0–100
• Calculation:

So, the PLC output is 50 units (e.g., 50.0 bar if measuring bar).

Putting It Together

• Network 1 (NORM_X): Converts raw sensor signal → normalized ratio (0.0–1.0).
• Network 2 (SCALE_X): Converts normalized ratio → engineering units (0–100).

This two‑step process ensures:

• Flexibility (any input range can be normalized).
• Accuracy (engineering values are scaled correctly).
• Simplicity (easy to reuse across different sensors and outputs).