The Machine Simulator (MS) is part of the EasyPLC software suite. It has many built-in machines that can be programmed. A simple conveyor is one of these machines. This is usually the starting point for learning about the machine simulator. This conveyor example will use two digital inputs and two digital outputs. A pallet will move back and forth on the conveyor. When the pallet is detected on each end it will stop and reverse direction. If both motors are started at the same time, the motors will burn up. This will be demonstrated. The machine simulator will allow you as the programmer to make mistakes before trying your program in the physical world.
The Machine Simulator (MS) is part of the EasyPLC Software Suite. This is a complete PLC, HMI, and Machine Simulator Software package. This PLC learning package includes a Machine Simulator (MS). This virtual 3D world with real-time graphics and physical properties can communicate to several different programmable logic controllers. (PLC) See below to receive a 10% discount off of this PLC learning package. Invest in yourself today.
Previously we have done the following:
Easy PLC Installing the Software – Video
Click PLC – Easy Transfer Line Programming – Video
Productivity PLC Simulator – Chain Conveyor MS – Video
Do-More PLC – EasyPLC Box Selection Program – Video
Click PLC EasyPLC Gantry Simulator – Video
Define the task: (Step 1 – Simple Conveyor)
The first step of PLC program development is to determine what has to be done.
The machine simulator has a demo mode for the built-in machines. This will allow you to watch the operation of the simple conveyor. The objective is to move the pallet through the roller conveyor, first to the right (PLC Digital Output 0) until the photocell located on the right side activates the digital input 0 to the PLC. Then activate the rotation of the conveyor rollers do the box moves to the left (PLC Digital Output 1) until the photocell on the left side will be activated (PLC digital input 1), then reverse the rotation of the rollers, repeating the process.
Select the Start button for the conveyor example.
Define the Inputs and Outputs: (Step 2 – Simple Conveyor)
The View IO displayed the inputs and outputs required for this simple conveyor.
The conveyor example will require 2 digital outputs and 2 digital inputs.
The following table will define the inputs and outputs (IO) and Modbus addresses in the Click PLC that we will use for this program.
Digital Type Description Click Address Modbus Address MS Start Address
WorkPartCreatorPallet
ConveyorDistrib Advance
Conveyor Y101 8225 8224
Pneumatic
Start PB Light
Note: The machine simulator will be offset by one on the Modbus Addresses.
Using the address picker in the Click PLC programming software will show you the set Modbus addresses for this controller. See the video below.
Develop a logical sequence of operation: (Step 3 – Simple Conveyor)
A flow chart or sequence table is used to fully understand the process the needs to be controlled. It must also answer questions like the following:
What happens when electrical power and/or pneumatic air is lost? What happens when the input/output devices fail? Do we need redundancy?
This step is where you will spend the majority of your time. Understanding everything about the operation will save you time. It will help prevent you from continuously re-writing the PLC program logic. Knowing all of these answers upfront is vital in the development of the PLC program.
This program seems straightforward at first. We will add delays before sending the pallet in the opposite direction. 500 milliseconds will be used. A first scan flag in the PLC will also be used to start the pallet moving in one direction after a power cycle.
Future programs could track the time between the sensors to show conveyor speed. It could also keep track of run time to ensure maintenance on the conveyor is done.
A PLC programmer must know how everything about the sequence and operation of the machine before programming.
Ask questions or view existing documentation to ensure that you know the logical steps to the machine operation.
Develop the Click PLC program: (Step 4 – Simple Conveyor)
Writing the ladder logic code for the PLC example will be the next step in our program development. We will be using the Click programming software and a Click PLUS PLC.
The Click PLC Series will take you through installing the program, communicating to the controller, instructions, and addressing the controller.
A static (fixed) IP address is used on the network to ensure that we know where the PLC is after power interruptions. Make a note of this address so we can enter the information in the EasyPLC simulator.
Save and transfer the PLC program to the Click. Ensure that the PLC is in Run mode.
Watch the video below to see this PLC program in action
Test the program: (Step 5 – Simple Conveyor)
We will be using Modbus TCP on our Click PLUS PLC to communicate to the EasyPLC Machine Simulator.
Call up the simple conveyor (0 1st Test) in start mode.
Select the configure button.
The digital inputs from MS to the Click PLC will be Y101 to Y102. This will start at address 8224 due to the offset of 1. Digital outputs from MS to the Click PLC will be X101 to X102. This will start at address 32 due to the offset of 1.
Select the OK button.
Select start driver and exit from the main menu.
Easy PLC machine simulator has a time frame that you can speed up or slow down the process to help you troubleshoot.
Download the Click PLC sample ladder logic program for the simple conveyor.
Watch the video below to see the five steps of program development applied to the simple conveyor. The machine simulator is one of the best applications to help you learn PLC programming.
EasyPLC Software Suite is a complete PLC, HMI, and Machine Simulator Software package. This PLC learning package includes the following:
Easy PLC – PLC Simulation that will allow programming in Ladder, Grafcet, Logic Blocks, or Script.
HMI System – Easily create a visual human-machine interface (HMI)
Machine Simulator – A virtual 3D world with real-time graphics and physical properties. PLC programs can be tested using the EasyPLC or through other interfaces. (Modbus RTU, TCP, etc.)
Machine Simulator Lite – Designed to run on Android Devices.
Machine Simulator VR – Virtual Reality comes to life so you can test, train or practice your PLC programming.
Purchase your copy of this learning package for less than $75 USD for a single computer install, or less than $100 USD to allow different computers.
Receive 10% off the price by typing in ACC in the comment section when you order. http://www.nirtec.com/index.php/purchase-price/
Learn PLC programming the easy way. Invest in yourself today.
Watch on YouTube: Click PLC Simple Conveyor EasyPLC
If you have any questions or need further information please contact me.
Thank you,
Garry
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