We will now program our Pneumatic Pusher simulator with the Click PLUS PLC. The Machine Simulator (MS) is a valuable component of the Machine Simulator Software Suite. It offers a range of built-in machines, including the pneumatic pusher machine, which effectively demonstrates various programming techniques. We will use the Click PLC programming software to showcase a sequencer application for this example.
In this scenario, two boxes on a conveyor belt are pushed onto the loading dock at a time with one pneumatic pusher. When eight boxes are accumulated on the loading dock, a second pneumatic cylinder pusher will move them into a crate. A logical sequence of steps will be implemented, with a counter controlling the progression. This fundamental approach to programming sequences applies to all PLCs.
We will use the free Click programming software and a Click PLUS PLC to program the Machine Simulator pneumatic pusher simulator. Communication between the software and the PLC will be established using Modbus TCP (Ethernet). The program sequencer offers a convenient and efficient means of controlling the automation system.
We will follow the five program development steps to guide you. These steps will provide a clear and structured approach to programming the sequencer. With that said, let’s dive right in and begin our journey into the world of pneumatic-pushing PLC program development.
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Previously, we have done the following:
Easy PLC Installing the Software – Video
EasyPLC Software Suite – Quick Start – 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
Click PLC Simple Conveyor EasyPLC – Video
EasyPLC Paint Line Bit Shift – BRX Do-More PLC – Video
Click PLC – EasyPLC PLC Mixer Programming – Video
Click PLC EasyPLC Warehouse Stacker Example – Video
– Operation Video
EasyPLC Machine Simulator Productivity PLC Robotic Cell – Video
EasyPLC Simulator Robotic Cell Click PLC – Video
Palletizing Conveyor Programming Do-More PLC – Video
Palletizing Conveyor Programming – Click PLC – Video
Product Quality Verification! Do-More PLC Sequencer – Video
Revolutionize Learning PLCs with Pallet 3D Sim! – Video
Robot Packing PLC Program Development – Video
Box Dumper Easily Learn PLC Programming – Video
Innovative Solution for Mixing Ink and Bottling – Video
Benchwork 1 Do-More Practice PLC Programming – Video
LS Electric XGB PLC Easy Transfer Program – Video
Do-More PLC Automatic Robot Packing Machine – Video
Latest Machine Simulator Modbus Server Driver – Video
Machine Simulator Modbus Server to C-More HMI – Video
Creating the Ultimate Automation Training Setup
– Part 1 – Video
– Part 2 – Video
Unlock Click PLC & Machine Simulator Integration – Video
Define the task: (Step 1 – Click Pneumatic Pusher)
The first step of a Click or any PLC program development is determining what must be done. Start the Machine Simulator (MS). Select the machine’s button on the main page or select machines from the main menu at the machine simulator window. All the available machines will now be displayed. Move your mouse over the “Pneumatic Pushers” machine. This is the machine that we will be programming. Three items will be displayed. Click the information button on the top right of the screen. This will show you a description of the pneumatic pusher machine. Select Close.
The pneumatic packing machine simulator has a demo mode. This will allow you to watch the operation of the pneumatic pusher so we can understand the basics of how this needs to function. Select the demo mode for the pneumatic pusher machine.
When two boxes are collected at the end of the small conveyor, the conveyor will stop. Both capacitive sensors will be on, indicating that the boxes are present. The cylinder one pneumatic pusher will advance for some time or until the piston one advanced sensor comes on. When cylinder one retracts, the small conveyor will start loading two more boxes again.
When the loading dock has eight boxes, the open cover will open. After the cover is opened, cylinder two’s pneumatic pusher will advance until the advanced sensor of piston two comes on. This ensures all of the boxes are pushed into the crate. When cylinder two retracts all the way, the open cover will close. The cycle can then start over again.
Move around the 3D virtual environment.
The icons on the top of the window allow you to move around this 3D environment. The first icon is the default selection. This will enable you to move around without bumping into the components. The last icon will automatically show you around this virtual environment. The first-person mode will mimic a person in your 3D learning world. The third person will show you an operator and their relationship to the pneumatic pusher machine. Once we understand what must be done, we can move on to the next step in developing the Click PLC program.
Define the Inputs and Outputs: (Step 2 – Click Pneumatic Pusher)
At the top of the pneumatic pusher machine simulator window, the View I/O will display the inputs and outputs required for this example. The outputs are on the left-hand side, and the inputs are on the right-hand side.
While still in demo mode, you can see the operation of the inputs and outputs.
The Pneumatic Pusher Machine Simulator will require six digital outputs and eight digital inputs. If you are unsure what the output or input is doing, start the pneumatic pusher machine in Start mode.
Select View IO at the top middle of the pneumatic pusher machine simulator window. Like our Click PLC connection, you can manually run the pneumatic pusher without control.
Clicking on the outputs will allow you to turn them on manually. You can then monitor the inputs to see their operation. The restart button on the top of the pneumatic pusher machine simulator window will reset the scene back to the start. The following table will define the inputs and outputs (IO) and Modbus addresses in the Click PLC we will use for this program.
| Digital Type | Description | Do-More PLC Modbus Address | Machine Simulator Modbus Address |
| PLC Output – MS Input | ADVANCE CYL 1 | 16485 – C101 | 16484 |
| PLC Output – MS Input | BACK CYL 1 | 16486 – C102 | 16485 |
| PLC Output – MS Input | SMALL CONVEYOR | 16487 – C103 | 16486 |
| PLC Output – MS Input | ADVANCE CYL 2 | 16488 – C104 | 16487 |
| PLC Output – MS Input | BACK CYL 1 | 16489 – C105 | 16488 |
| PLC Output – MS Input | OPEN COVER | 16490 – C106 | 16489 |
| PLC Input – MS Output | PISTON 1 BACK | 16585 – C201 | 16584 |
| PLC Input – MS Output | PISTON 1 ADV | 16586 – C202 | 16585 |
| PLC Input – MS Output | PISTON 2 BACK | 16587 – C203 | 16586 |
| PLC Input – MS Output | PISTON 2 ADV | 16588 – C204 | 16587 |
| PLC Input – MS Output | COVER CLOSED | 16589 – C205 | 16588 |
| PLC Input – MS Output | INPUT 5 | 16590 – C206 | 16589 |
| PLC Input – MS Output | CAPACITIVE 1 SIGNAL | 16591 – C207 | 16590 |
| PLC Input – MS Output | CAPACITIVE 2 SIGNAL | 16592 – C208 | 16591 |
Note: The machine simulator will be offset by one on the Modbus Addresses.
See the video below for the demo mode and for determining inputs and outputs.
Develop a logical sequence of operation: (Step 3 – Click Pneumatic Pusher)
A flow chart or sequence table is used to understand the process and must be controlled thoroughly. It must also answer questions like this:
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 most 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 these answers upfront is vital in developing the PLC program.
Our Click PLC pneumatic pusher example can be broken down into steps.
Our sequence table for the pneumatic pusher will show the input signals on the left side and the output signals on the right.
The value of the counter is shown with each step. Each step will show the conditions that need to occur for the next step to operate.
We will load two boxes at a time on the conveyor belt. We will load eight boxes onto the table using the first pneumatic pusher. After the cover opens, the second pneumatic pusher will put the boxes into the crate. When the pusher returns, the cover closes, and the sequence starts over.
A PLC programmer must know everything about the sequence and operation of the machine before programming.
Ask questions or view existing documentation to ensure you know the logical steps to the machine’s operation.
Develop the Click PLC program: (Step 4 – Click Pneumatic Pusher)
The next step in our program development will be writing the ladder logic code for the Click PLC example. We will use the free Click programming software with the Click PLUS PLC. The Click Series will install the program, communicate the instructions, and address the controller.
Using the Address Picker, enter as many address names as you think you will use in the program. As we write the program, we can continuously document the additional addresses. To access the Address Picker, select it from the main menu | Program | Address Picker…
This can also be accessed in the navigation window in the program tab under the Ladder Program heading.
The first rung will control the start and stop bit for the sequencer. This is an internal bit C1. This bit will then be used as a condition in the entire program. A counter is used as the primary control for the steps in our sequencer. We compare the steps and input conditions that will move the program to the next step.
The reset of our sequencer (counter) will come from the first scan of the PLC or when step 13 of our program has happened.
Our start-stop bit and the sequence number will control the outputs for our program. Conditions for the PLC outputs can also be placed on this rung. For the conveyor to be turned on, piston one must be back.
Cylinder one control advanced output must also have a timer. This is because the cylinder may not extend when multiple boxes are on the table. So the extend sensor may not signal. We also may require a quick 500-millisecond timer to ensure separation in the advance and return signals within our sequence.
See the video below to watch the programming of this sequencer.
Sequence numbers will determine when outputs will activate as we go through all the physical outputs.
The advantage of using a counter as the control for the sequencer is that as we program, we can test our logic.
This is the end of the ladder logic for our pneumatic pusher program. Watch the video below to see how this is created with the Click PLC Programming software.
Select the “Com Port…” under the Setup selection on the main menu.
The available ports on the Click PLC are displayed. Using Modbus TCP (Ethernet), we can set up either the WLAN (wireless local-area network) or Port 1 (Ethernet). Select setup for port 1.
Note: If you want to go directly to the Com Port Setup details window, select Com Port 1 Setup under the CPU Configuration on the Function Tab of the navigation window.
A static IP address will be used for our Click PLC. This ensures that the IP address on the network can always be found. Note the IP address we are using. This will later be used for the Pneumatic Pusher Machine Simulator connection.
Under the Setup menu on the main screen, you will also see Modbus TCP… This will show us the default parameters for our Ethernet port and allow us to enable the Modbus TCP Server. This is enabled by default on the controller. We will leave everything at its default values.
Our Click PLUS PLC is now set to communicate to the EasyPLC Machine Simulator Modbus TCP Client.
Download the Click ladder logic program to the Click PLUS PLC. Ensure that the PLC is in run mode. Watch the video below to see this Click PLC program in action.
Test the program: (Step 5 – Click Pneumatic Pusher)
We will use Modbus TCP on our Click PLUS PLC to communicate with the EasyPLC Machine Simulator. Call up the pneumatic pusher machine simulator in start mode.
The status of the machine simulator will be at the bottom left of the screen. Currently, we have no PLC connected. Select IO Drivers at the top of the screen.
The machine simulator IO number will be displayed. Ensure we select more IO than required for our pneumatic pusher machine. The EasyPLC driver is selected by default.
Under the driver pull-down menu, select “ModBusDriver.” This driver will communicate Modbus TCP (Ethernet) and Modbus RTU (Serial). Select the down arrow on the driver’s name.
Select the configure button.
We can now enter the information for our Modbus driver. Select TCP/IP. This means the Ethernet port on the computer will communicate with the Click PLC. The digital inputs from MS to the Click PLC will be C101 to C106. This will start at address 16484 due to the offset of 1. Digital outputs from MS to the Click PLC will be C201 to C208. This will begin at address 16584 due to the offset of 1. Select the OK button.
You will now see the inputs and outputs specified for the Modbus driver. We can now manually assign the driver outputs to the PLC inputs and the driver inputs to the PLC outputs. However, the automatic assignment works well and will save you time.
Select Automatic Assignment from the driver option in the main menu.
This will automatically assign the PLC IO to the Machine Simulator IO. Select Start Driver and exit from the main menu.
On the bottom left side of the window, the driver communicates to the Click PLUS PLC. Select view IO to know the input and output status of the machine simulator.
Ensure that the Click PLC is in run mode. We can see the operation of our pneumatic pusher machine. Please select the first switch on our Click PLC to start the sequencer. The digital inputs and outputs of the MS will correspond to the PLC controller.
Using the Data View window of the Click programming software, we can also watch the inputs and output operations.
Using a Machine Simulator (MS) to test the program will ensure that our program works. Troubleshooting is quickly done without damage to any physical hardware.
You can practice your modification and debugging by modifying the pneumatic pusher operation in the following way:
– Add a start-stop control panel to the machine.
– Add a jog button to the control panel to sequence through the steps.
– Calculate the rate of the pneumatic pushers per hour. This can be used later on to create a maintenance program.
Let me know how you make out in the comments below.
Download the Click PLC sample program and sequence table here.
Watch the video below to see the five steps of program development applied to the pneumatic pusher machine. The machine simulator is one of the best applications to help you learn PLC programming.
Watch on YouTube: Master the Pneumatic Pusher Simulator Now!
Machine Simulator (EasyPLC) Software Suite is a complete PLC, HMI, and Machine Simulator Software package. This PLC automation learning package includes the following:
Easy PLC – PLC Simulation allows 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 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.
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If you have any questions or need further information, please contact me.
Thank you,
Garry
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