Problem 1:
In a company, an electric bell is used as a signal to tell the staff that it is
time to start work, go for teabreak, go for lunch and go home. A switch is
used to activate the bell. The bell rings when the switch is pressed. It will
go off when switches released.
LADDER DIAGRAM:
X0
Y0
CONTROL DIAGRAM:
PB1
START BELL
HARD WIRING:
PB1
X0 Y0
START
X1 Y1 BELL
X2 Y2
X3 Y3
X4 Y4
S/S COM
INPUT:
X0
PROBLEM 2:
A siren will sound when a switch is pressed. It will sound continuously even
when the activating force is removed. It will go off when the switch is
reset.
LADDER DIAGRAM:
X0
SET M0
X1
RST M0
M0
Y0
PB1
START
PB2
R
STOP
M0 S
CONTROL DIAGRAM:
PB1
START
PB2
X0 Y0
X1 Y1 SIREN
STOP
X2 Y2
X3 Y3
X4 Y4
S/S COM
HARD WIRING:
PROBLEM 3:
In a chemical plant, an indicating lamp will be lighted when the pressure
and the temperature rise above a certain level. These two conditions are
simulated by using push-button switches PB1 and PB2. In other words,
when both PB1 and PB2 are pressed, the lamp will be lighted. When either
one of them is released, the lamp will go off.
X0 X1
Y0
LADDER
DIAGRAM:
CONTROL DIAGRAM:
PB1 PB2
LAMP
PB1
PB2
X0 Y0
X1 Y1
LAMP
X2 Y2
X3 Y3
X4 Y4
S/S COM
HARD WIRING:
PROBLEM 4:
In a production line, an indicating lamp will be lighted whenever an
operator presses a push-button. This is to capture the attention of the line
leader whenever they encounter a problem. Here, three stations are
simulated using push-button switches PB1, PB2 and PB3 respectively.
X0
Y0
X1
X2
LADDER DIAGRAM:
PB1
PB2
PB3
CONTROL DIAGRAM:
PB1
PB2
X0 Y0
PB3
X1 Y1
LAMP
X2 Y2
X3 Y3
X4 Y4
S/S COM
HARD WIRING:
PROBLEM 5:
In an electrical parts warehouse, a normally-closed limit switch is used to
send a signal to the burglar alarm when the door is opened. The alarm will
not sound if the door is closed. The burglar alarm system is activated or
de-activated by a key selector switch.
LADDER DIAGRAM:
X0 X1
Y0
CONTROL DIAGRAM:
KEY
SWITCH
ALARM
LS1
KEY
SWITCH
ALARM
LS1 X0 Y0
X1 Y1
X2 Y2
X3 Y3
X4 Y4
S/S COM
HARD WIRING:
PROBLEM 6:
In a printing firm, a cutter is used to cut the side edges of the papers. This
cutter is controlled by a pneumatic cylinder. For the safety of the operator,
the cutter will move down only when both push-button switches PB1 and
PB2 are pressed and also a safety cover must be closed. This safety cover
is closed manually and a limit switch is used to detect the closed position.
When one of the push-button is released or when the safety cover is
opened, the cutter will immediately return to its top position. The cylinder
is controlled by a single solenoid spring return valve.
LADDER DIAGRAM:
X0 X1 X2
Y0
CONTROL DIAGRAM:
PB1 PB2 SOLENOID
LS1 CUTTER
PB1
PB2 SOLENOID
CUTTER
X0 Y0
LS1
X1 Y1
X2 Y2
X3 Y3
X4 Y4
S/S COM
HARD WIRING:
PROBLEM 7:
Three sensors S1, S2 and S3 are used to detect short, medium and long
workpieces on a conveyor system. A red, green and blue indicating lamp
will be lighted if a short, medium and long workpiece is detected
respectively. In other words, if sensor S3 and not S1 and not S2 is
triggered, a short workpiece is detected and therefore a red indicating
lamp will be lighted. If sensor s2 and s3 and not S1 are triggered, a
medium workpiece is detected and therefore a green indicating lamp will
be lighted. If sensor S1 and S2 and S3 are triggered, a long workpiece is
detected and therefore a blue indicating lamp will be lighted.
X3 X1 X2
Y0
X3 X2 X1
Y1
X1 X2 X3
Y2
LADDER DIAGRAM:
S3 S1 S2
Y0
RED LAMP
S3 S2 S3
Y1
GREEN LAMP
S3 S2 S3
Y2
BLUE LAMP
CONTROL DIAGRAM:
RED LAMP
S1
S2
X0 Y0 GREEN LAMP
X1 Y1
S3
X2 Y2
X3 Y3
BLUE LAMP
X4 Y4
S/S COM
HARD WIRING:
PROBLEM 8:
A huge steel door is installed in a deep mining tunnel. This door may be
opened or closed by two sets of push-button switches. One set from inside
and the other set from outside. The sliding unit is controlled by a double
solenoid valve.
LADDER DIAGRAM:
PROBLEM 9:
The opening and closing of a door (similar to a bus door) is activated by
using two push-button switches PB1 and PB2. Switch PB1 is for opening
and PB2 is for closing of the door.
The cylinder is controlled by:
a) a double solenoid valve
b) a single solenoid spring return valve
X
LADDER DIAGRAM: A Double Solenoid Valve
CONTROL DIAGRAM:
PB1
PB2 SOLENOID
X0 Y0
X1 Y1
X2 Y2 SOLENOID
X3 Y3
X4 Y4
S/S COM
HARD WIRING:
PB1
PB2 SOLENOID A
X0 Y0
X1 Y1
X2 Y2 SOLENOID B
X3 Y3
X4 Y4
S/S COM
LADDER DIAGRAM: Single Solenoid Spring Valve
PB1
M0
PB2
RST M0
M0
Y0
SOLENOID A
CONTROL DIAGRAM:
PB1
PB2
X0 Y0
X1 Y1 SOLENOID A
X2 Y2
X3 Y3
X4 Y4
S/S COM
HARD WIRING:
PROBLEM 10:
By pressing a start button (with the cylinder initially retracted), a
workpiece is pushed away from the gravity feed magazine onto a
conveyor system. The cylinder returns automatically when it has reached
the fully extended position. Fully extended and retracted positions are
sensed by reed switches RS1 and Rs2. The cylinder is controlled by a
single solenoid spring return valve.
PROBLEM 11:
In a production plant, pneumatically actuated window is mounted at the
roof to control the ventilation. The opening and closing of this window is
controlled by two push-button switches PB1 and PB2. Switch PB1 is for
opening and PB2 is for closing of the window. It must be possible to stop
the window at any position during opening or closing. A lamp will be
lighted to show the closed position. Direct or indirect control method can
be used.
PROBLEM 12:
A workpiece is manually placed in the clamping device. Upon activation of
a push button PB1, the clamping cylinder clamps the workpiece another
push button PB2 is used for declamping.
Additional conditions:
i) Clamping operation is carried out only when a workpiece is present
ii) It must not be possible to do declamping when drilling is in
operation
iii) The clamping speed must be adjustable (low speed is preferred)
iv) Declamping operation must be very fast
The clamping cylinder is controlled by :
a) a single solenoid valve
b) a double solenoid valve
PROBLEM 13:
When sensor S1 senses a container, a pneumatic operated valve will open
and allows liquid from the tank to flow into it. The valve closes
automatically after a time delay of 5 seconds. After which the container
will be transported to another station. For safety reasons, the valve closes
immediately when the container is removed before the time delay
elapsed. Time delay starts when sensor S1 is triggered. The valve is
controlled by a rotary actuator which is activated by a single solenoid
spring return valve.
PROBLEM 14:
A stamping operation is to be carried out upon the activation of a start
button. Cylinder will automatically retract if the stamping pressure reaches
3 bars. An activation of the stop button will stop the stamping operation.
The cylinder is controlled by a single solenoid spring return valve.
PROBLEM 15:
A working life cycle test is to be carried out on a double acting cylinder.
When a start-button switch is pressed, this cylinder will extend and retract
continuously. When 10000 cycles is reached, the whole operation stops. It
can only be restarted if a reset-button switch is activated. One cycle refers
to the extension and the retraction of the cylinder. The extended and
retracted position of the cylinder are sensed by reed switches RS1 and
RS2. A stop-button switch can be used to stop the operation before the
10000 cycles are up. An interrupted operation can be restarted by
pressing the start-button again.
PROBLEM 16:
The boxes arrive on a roller conveyor and are transported onto the second
roller conveyor by cylinder A and B.
Cylinder B must not return until cylinder A has reached the retracted
position. The sequence will begin when sensor S1 detects a workpiece.
Each cylinder is controlled by a double solenoid valve.
PROBLEM 17:
Parts are manually placed in a receptacle. A pneumatic cylinder A pushes
the receptacle under the drilling operation. The drill feed unit is controlled
by a pneumatic hydraulic actuator B. After drilling, cylinder A must not
return until drill feed unit has reached its start position. The sequence will
begin when a start- button is pressed. Each cylinder is controlled by a
double solenoid valve.
