Robot Packing PLC Program Development

Name: Robot Packing PLC Program Development
Uploaded: 2024-01-29T10:50:39+00:00
Duration: 18 min 24 s

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Hi everyone, today we are going to be looking at the Robot Packing PLC program development
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The Machine Simulator, or MS, is a valuable component of the EasyPLC software suite
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It offers a range of built-in machines including the Robot Packing machine, which effectively
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demonstrates various programming techniques. We will use the CLICK PLC programming software to showcase a sequencer application for this example
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In this scenario, the robot is tasked with collecting five bags and loading them onto
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a cardboard box. A logical sequence of steps will be implemented to accomplish this, with the counter controlling
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the progression. This fundamental approach to programming sequencers applies to all PLCs
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To program the EasyPLC Robot Packaging Machine Simulator, we will use the free CLICK programming
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software and a CLICK PLUS PLC. Interference between the software and the PLC will be established using Modbus TCP or Ethernet
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The program sequencer offers a convenient and effective means of controlling the automation system
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We will follow the five program development steps to guide you through the process
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These steps will provide a clear and structured approach to programming the sequencer
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With that said, let's dive right in and begin our journey into the world of Robot Packing
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PLC program development. Detailed information contained in this video can be found at accautomation.ca
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A link has been put in the description below. If you have not watched the other videos yet, there will be links in the description below
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that will start you with video 1. There will be links to the rest of the videos in the series as well
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Step 1. Define the Task The first step of a CLICK or any PLC program development is to determine what must be done
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Start the EasyPLC Machine Simulator or MS. Click the Start button on the main page or select Machines from the main menu at the
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Machine Simulator window. All of the available machines will now be displayed
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Click on the 30 Packing Auto. This is the example we will be programming
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To the left of the screen, information will be displayed on how the robot packing machine
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needs to function. A conveyor belt supplies bags containing food that must be packed into cardboard boxes
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Another belt supplies the cardboard boxes to fill the food bags. The objective is to manipulate the automatic packaging system to fill each cardboard box
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with 5 food bags. The packing robot has two working modes, continuous loading or loading in different positions
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In the continuous work mode, the PLC must indicate a lowering speed to match the rate
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of supply of food bags. In the position mark mode, once each bag has been loaded, the PLC must indicate new loading
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positions to the robot so that it lowers and a new bag can be loaded
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Use the two photo cells installed on the bag conveyor to give the appropriate instructions
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to the packing robot. Once the 5 bags have been loaded, the bag conveyor must be stopped and the robot clamping
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system must be closed so that the bags do not fall when they are inserted into the cardboard box
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At the same time, the PLC must manage the cardboard box conveyor to position it correctly
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in the loading position, stopping the advance with the stop cylinder rod and using a pneumatic
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blocker so that the box does not move during the loading operation
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Once loaded, release the box to load a new empty one. The robot packing machine simulator has a demo mode for this built-in machine
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This will allow you to watch the operation of the robot packer. Select the demo mode for the packing auto robot
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The demo mode will show you the basics of the robot packing operation
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Move around this 3D virtual environment. The icons on the top of the window will allow you to move around this 3D environment
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The first icon is the default selection. This will enable you to move around without bumping into components
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The last icon will automatically show you around this virtual environment. The first mode will mimic a person in your 3D learning world
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The third person will show you an operator and their relationship to the auto packing machine
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Once we understand what must be done, we can move on to the next step in developing the
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CLICK PLC program. Step 2. Define the inputs and outputs
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At the bottom of the machine simulator window, the VUIO will display the inputs and outputs
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required for this robot packing example. While still in demo mode, we can see the operation of the inputs and outputs
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The EasyPLC-30 packing auto will require 12 digital outputs and 13 digital inputs
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If you are unsure of what an input or output is doing, start the robot packing machine
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in start mode
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Select the VUIO at the bottom middle of the auto packing machine simulator window
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You can manually run the auto packer without any control or PLC connected
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Clicking on the outputs will allow you to turn them on manually. You can then monitor the inputs to see their operation
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The reset button at the bottom of the machine simulator window will reset the machine back
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to the start. Step 3. Develop a logical sequence of operation. A flowchart or sequence table is used to understand the process that must be controlled thoroughly
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It must also answer questions like what happens when electrical power or pneumatic air is lost
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What happens when inputs and output devices fail? Do we need redundancy
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This step is where you will spend most of your time. Understanding everything about the operation will save you time
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It will help prevent you from continuously rewriting the PLC program logic
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Knowing all these answers up front is vital in developing the PLC program
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Our CLICK PLC robot packing example will break down into two basic parts
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The conveyor controlling the empty box and the robot collecting the bags
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When the start button is selected, the box conveyor will make a box and position it for
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the robot to fill the bags. When the box is filled with the bags, it is sent down the conveyor belt and another box
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is positioned for the robot. Our sequence table for the robot will show the input signals to the left side and the
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output signals to the right. The value of the counter is shown with each step
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Each step will show the conditions that need to occur for the next step to operate
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A PLC programmer must know everything about the sequence and operation of the machine
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before programming. Ask questions or view existing documentation to ensure you know the logical steps to the
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machine's operation. Step 4. Develop the CLICK PLC program
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The next step in our program development will be writing the ladder logic code for the CLICK
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PLC example. We will use the free CLICK programming software with the CLICK PLUS PLC
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The CLICK series will install the program, communicate to the controller instruction and address the controller
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Using the address picker, enter as many address names as you can think of that you will use
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in the program. As you write the program, we can always go back and document the additional addresses
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To access the address picker, select it from the main menu, Program, Address Picker
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This can also be accessed in the navigation window in the Program tab under the Ladder
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Program heading. The first rung will start and stop the robot packing machine by turning on the internal
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bit C1. This bit will then be used as a condition in the entire program
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The next two rungs are part of the control for the boxes on the conveyor
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If the robot packing machine bit is on and we do not have a photocell 3 signal, activate
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the cylinder stop. This resets when the box is full. A timer ensures that the box is stopped by the cylinder rod
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This creates a half second delay after the photocell 3 signal is seen
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The box conveyor will stop after this. The conveyor will start again when the box is full and the cylinder stop has returned
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The pneumatic push ensures the empty box remains still when the robot fills it
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This is engaged after the timer expires to ensure the box is positioned correctly
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Timer 2 is activated when the box is full and the cylinder stop is back. It is a half second timer
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The box full bit is set from the counter sequencer. Timer 16 will activate the box once it is complete
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Timer 3 is used to reset the full box bit. This happens 1.5 seconds after photocell 3 no longer sees the signal
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A counter is used to control the sequence of the robot. The previous step and table give us conditions for each counter increment
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We compare the counter or accumulator to set the outputs
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In the case of the robot home output signal, the counter will be greater than or equal
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to 0 and less than or equal to 9. It will also be on when it is greater than or equal to 11
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We can see this by looking at the sequence table. The work part creator will create the bags along the conveyor belt
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This will occur when the counter equals 0, 2, 4, 6 or 8
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Robot 1 load position will activate when the counter is 1. A timer ensures that the position is reached before the next step
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Robot 2, 3 and 4 load positions will activate at the appropriate counter value
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Individual timers ensure that the position is reached before the next step
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The closed grip on the robot activates when the counter is equal to 9 and 10
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This holds the bags so that they do not fall when moving to the box
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When the counter equals 10, the robot is sent to the unload position
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A timer ensures that the position is reached before the next step
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The robot home reset timer ensures that the home position is reached before starting the
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robot sequence over again. This is the end of the ladder logic for our packaging robot program
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Select the COM port under the Setup selection on the main menu
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Available ports on the CLICK PLC are displayed. Using Modbus TCP Ethernet, we can set up either the WLAN, Wireless Local Area Network, or
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Port 1 Ethernet. Select Setup for Port 1. Note that if you want to go directly to the COM port setting details window, select COM
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Port 3 Setup under the CPU Configuration on the Function tab of the main navigation window
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A static IP address is used for our CLICK PLC. This ensures that the IP address on the network can always be found
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Note the IP address we are using. This will be later used for the EasyPLC Robot Packing Machine Simulator connection
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Under the Setup menu on the main screen, you will also see Modbus TCP
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This will show us the default parameters for our Ethernet port and allow us to enable the
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Modbus TCP server. This is enabled by default on the controller. We will leave everything as their default values
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Our CLICK PLC is now set to communicate to the EasyPLC Machine Simulator Modbus TCP client
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Download the CLICK Ladder program to the CLICK PLC. Ensure that the PLC is in Run mode
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Step 5. Test the program. We will use Modbus TCP on our CLICK PLUS PLC to communicate with the EasyPLC Machine Simulator
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Call up the Robot Packing Machine Simulator in Start mode. The status of the machine simulator will be at the bottom of the screen
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Currently, we have no PLC connected. Select I0 drivers on the bottom middle of the screen
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The Machine Simulator I0 number will be displayed. Ensure we select more I0 than the number required for a Robot Packing Machine
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The EasyPLC driver is selected by default. Under the Driver pull-down menu, select Modbus Driver
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This driver will communicate Modbus TCP or Ethernet and Modbus RTU serial
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Select the Configure button. We can now enter the information for our Modbus driver
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Select TCP IP. This means the Ethernet port on the computer will communicate with the CLICK PLC
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Digital inputs from MS to the CLICK PLC will be C101 to C112
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This will start at address 16484 due to the offset of 1
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Digital outputs from MS to the CLICK PLC will be C201 to C213
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This will begin at address 16584 due to the offset of 1
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Select the OK button. You will now see the inputs and outputs specified for the Modbus driver
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We can now manually assign the driver outputs to the PLC inputs and the driver inputs to
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the PLC outputs. However, the automatic assignment works well and will save you time
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Select Automatic Assignment from the Driver option in the main menu. This will automatically assign the PLC I.O. to the Machine Simulator I.O
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Select Start Driver and exit from the main menu. On the bottom left side of the window, the driver communicates to the CLICK PLC with
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a green light. Select View I.O. to know the input and output status of the Machine Simulator
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Ensure that the CLICK PLC is in Run mode. We can see the operation of a robot packing machine
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Select the Start button on the control panel and ensure the Emergency Stop is not on
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The digital inputs and outputs of the MS will correspond to the PLC controller
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Using the Data View window of the CLICK programming software, we can also watch the inputs and outputs operation
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Using Machine Simulator or MS to test the program will assure that your program works
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Troubleshooting is quickly done without damage to any physical hardware
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You can practice your modification and debug by modifying the robot packing operation in
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the following way. Add a stack light to indicate the operation of the robot packing machine
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Add a Jog button to the control panel to sequence through the steps
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Calculate the rate of full boxes coming out of the robot packing machine in boxes per hour
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Let me know how you made out in the comments below. If you enjoyed this video, please hit the like button below
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If you have any questions about the video, please leave a comment below and I'll do my best to answer it
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Thanks so much for watching, I will see you next time. Stay safe

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Robot Packing PLC Program Development