2010

University of Jordan
Faculty of Engineering and Technology
Mechatronics Engineering Department

Mechatronics System Design Lab

Experiment no. 1
Control of a four-level elevator system
using a programmable logic controller

Prepared by: Eng. Rasha Noufal

Experiments No. 1 Control of a four-level elevator system

Control of a four-level elevator system using

a programmable logic controller

Objectives:
This Experiments on the design and implementation of a PLC-based controller for a four
level elevator. The PLC used is an Mitsubishi PLC FX3U-32MR with 16 inputs and
outputs. The design incorporates an intelligent controller that services all the requests in
an energy-saving way, rather than on a first-come, first-served basis.

Following are the objectives of the experiment:

- To learn about the elevator hardware.
- To learn how to write a simple PLC program to move the elevator car.
- To learn how to write a sequence of action using ladder logic.
- To understand how control an elevator using a more complicated algorithm.

Introduction:
Elevator provides an advanced application with which students may study the use and
programming of programmable logic controller (PLC). The advanced features of the
elevator also allow complex digital control techniques to be investigated.

A. Overview and basic features

The motorized elevator car can be controlled (using an external controller) to move
between four floors in response to request from call pushbuttons located at each
floor and within the elevator car. The car door is motorized so an arrival at floor it
can be opened to allow passengers to enter/leave. Logic sensors are located on
each floor to indicate the presence of the car. These sensors also provide advance
warning of arrival as the car approaches each floor to allow the car to be slowed
prior to arriving at the destination floor.
The internal motor controller unit provides closed loop motor speed and current
and has both logic and analogue interfaces. This allows the elevator to be
controlled by a basic PLC using only digital I/O (a minimum of 16 input and 16
outputs) as a simple digital output can be used to request a fixed car speed. More
sophisticated control may be implemented if analogue I/O is available, as the
elevator interface provides signals for motor speed and current demand, motor
speed feedback and car position feedback.

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B. Drive motor arrangement

The elevator car is raised and lowered by a dc motor via a 200: 1 gearbox which is
coupled to a toothed drive sprocket (see Figure 1). One end of a toothed drive belt
is connected to the car and the other end is connected to a counterbalance weight
which balances the car at about 40% load.

A mechanical brake (driven by a solenoid) operates on the winder motor so that

the car can be held in position. The brake is normally applied when the brake
release input is held low or left floating and also when the unit is unpowered.
Driving the brake release input high releases the brake.

C. Elevator car
The elevator car door is motorized and can be operated using the door control
signal input. Taking this input high opens the door. Taking it low or leaving it
floating closes the door. The door motor is controlled by an internal circuit which
responds to the door control input by opening or closing the door as required and
then removes power from the door motor automatically.
Micro switches detect the door status and door open / door closed signals are
made available at the rear panel for use by the external controller.
Visual indication of the position of the elevator car as it arrives at each floor is
provided by LEDs on the front of the unit.
A set of weights is provided that can be placed inside the car to simulate varying
passenger loads.

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D. Call pushbuttons
Elevator call pushbuttons are provided for each floor with separate up/down
pushbuttons for Floor 2 and Floor 3. This enables the external controller to
differentiate between requests for upward or downward travel and allows more
sophisticated algorithms to be implemented. A separate set of floor request
pushbuttons is provided on front panel to represent the request pushbuttons inside
the car.

Figure 2

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E. Interface with external PLC

The elevator is connected to the external PLC controller via a set of connectors
located on the rear panel, see Figure 3. Stranded insulated cable 7/0.2 or similar is
recommended for these connections.

Figure 3

F. Interfacing with Mitsubishi FX3U-32MR

The Mitsubishi PLC specified above is a complete unit consisting of 16 Sink or
Source inputs and 16 Relay outputs. This is the recommended minimum digital I/O
required for the Elevator assignments listed in this manual. An equivalent
Mitsubishi PLC may be used that has a transistor source output, but the output
wiring configuration will differ slightly from that given in the following wiring table .

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Table 1: Mitsubishi FX3U-32MR connection table

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Preliminary to Assignments

Basic control sequences

There are four basic sequences required to control car movement: initialization, depart
from a floor, arrive at a floor, and handle floor re uses. These are briefly described below.

A. Initialization
The external controller must be able to identify the position of the car in order to
determine in which direction to move. When using a logic-only controller which
does not receive continuous position information from the elevator, an
initialization routine must be executed when the controller runs for the first time
to identify the starting position.

B. Arrive at a floor
The sequence of operations is to sense arrival, slow down and stop. The brake
is then applied and the door opened.
The steps are as follows:
1. Poll the destination floor sensor to detect the approach signal
2. When the signal is received, reduce car speed to minimum
3. Poll the destination floor sensor to detect the arrival signal
4. When the signal is received, set the speed to zero and apply the brake
5. Sound the arrival chime
6. Turn off floor call LEOs
7. Turn off up/down arrow LEOs
8. Open the car door

C. Depart from floor

The departure sequence is as follows:
1. Close the car door
2. Set the motor direction
3. Turn on the appropriate up/down arrow LEOs
4. Release the brake
5. Set the motor to the desired speed

D. Floor request handling

Handling floor requests can be a complex task. Multiple requests may be made
simultaneously and requests may also occur whilst the car is in transit, possibly
requiring intermediate stops. A simple handler algorithm is described below.

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Register the first floor request that is received and ignore any further requests.
Go to the floor selected by the passengers (via the car floor request switch),
then poll for further requests.

Poll for requests on floor call and car switches:

Register the first request received and ignore any further requests.
Turn on the floor acknowledge LED for the appropriate request switch.
Determine the current position of the car (if not available, perform initial floor
seek).
If not at correct floor, perform depart from floor routine.

Perform arrive at floor routine:

Allow passengers to leave/enter the car.
Poll only the car floor request switches for the destination floor.
If no request within a set time, close the door and return to start of sequence.
If car request received, perform depart from floor routine.

Perform arrive at floor routine :

Poll for further requests on car switches only.
If no requests within a set time, close the door and return to start of sequence

Experiment Instructions:

A. Assignment 1: Familiarization

Objectives
- To learn about the elevator hardware.
- To learn how to connect the PLC to the elevator.
- To learn how to load a sample program into the PLC and start the program.
- To learn how to run the elevator test routine.

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Practical 1: Elevator Hardware

This practical is to learn about the elevator hardware. Refer to Figure 4, which
shows the main elevator parts.
Identify all components

Figure 4

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Practical 2: Using the PLC Software

The software you use to load programs to the controller depends on the type of
controller you are using.

Running the Elevator Test Routine

The elevator is supplied with a test procedure. This can be used to:
- Check the controller is connected to the hardware properly
- Check that each of the components are functioning successfully

The following steps are performed:

Step number Operation Times (sec.)

1
2
3
4
5
6
7
8
9
10
11
12
13

B. Assignment 2: PLC Fundamentals

Objectives
- To learn about the PLC inputs and outputs.
- To learn about the idea of a latch
- To learn how to use time delay to show an indicator.
- To learn how use elevator bell.
- To learn about Master Control Relay function.

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Practical 1: A Simple Program

Write a PLC program to perform the following task:
Make the bell sound when the Floor 1 car pushbutton is pressed.
The bell will ring for as long as the alarm bit is connected to be high.

Practical 2: Latches
Write a ladder diagram given below to your PLC then found the function of a
program.

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Practical 3: Using a Timer

This practical introduces the timer.

There may be several different types of timer available on your controller. The TON
and TOFF timers are the most important. The TON timer which means 'Timer On'
waits until a particular input has been set to high for a specified length of time. The
TOFF, meaning 'Timer Off activates a particular output for a set length of time.
The action of pressing Elevator Car pushbutton floor 1 lights the Car Direction Up
arrow For ten seconds.
Each timer has three possible outputs:
EN - Enabled bit
ON - Time done bit
TT - Timer timing bit
Write a program to perform the function described above.

Practical 4: Master Control Relays

This practical introduces the concept of the Master Control Relay and how
they can be used to control the flow of a program. The Master Control Relay
allows parts of a ladder logic program to be turned on and off allowing the
program to only perform the operations that are required. This can be particularly
useful with a long program.

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Consider the following scenario:

When the car pushbutton for Floor 1is pressed, a lamp for the higher floor is
displayed. For example, when the car Floor 1pushbutton is pressed for the first
time the lamp for Floor 1 will be highlighted. When it is pressed again the lamp for
Floor 1 and 2 are /it. When all floor lamps are /it and the pushbutton is pressed
again, all floors are extinguished.

This problem is represented using the following flowchart:

Each box has been labeled with a flowchart operation number, F1 through F10.
Using the flowchart, a program can be derived where the Master Control Register
is turned on and off using the state bits.

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C. Assignment 3: Elevator Initialization

Objectives
- To learn about the elevator initialization procedure.
- To learn about how to detect which floor the elevator is currently sitting at.

Practical 1: Initialization
When you turn on the PLC controller for the first time it does not know what state
the elevator hardware is set to. The elevator could be sitting between levels and
the car door could be open.
Before starting to control the elevator, the PLC must set the elevator to a known
state. This is achieved through an initialization routine.
Using the detailed information given below, write a program to perform an
Initialization routine that can be used in future exercises.

his procedure will form the basis of a subroutine. It should be executed before a
main program begins.

A recommended initialization routine is described by the following flowchart:

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In the real world, separate sensors would be used for above, below, and at each
floor. In this trainer, however, to reduce the number of PLC inputs required, a
single sensor for each floor is combined with the three-finger gate mounted to the
car. This change is compensated for in the PLC programs.
It is important to understand how a floor level sensor operates. Figure 5 shows the
design of the car floor level sensor. The car movement gate is fixed to the car and
a light sensor is fixed at each of the four floor levels. As the car reaches a floor the
car movement gate interrupts the light beam to the light sensor. A signal as shown
on the right hand side of the of the diagram is presented to a PLC input, changing
state as the light beam to the sensor is interrupted by the car passing a floor level.

Figure 5

Set the elevator car at the top floor using the Manual switch and look to the left
through the transparent front cover at the horizontal bars running from front to back
at each floor level and you will see the slotted light sensor for each floor. If you look
underneath the elevator car on the left hand side you will see the car movement
gate in the slot of the light sensor.
If the car is at the bottom of the elevator (level 1), no signal is received since the
light source is blocked. If the car is not at the level or is approaching a level, the
level sensor to the PLC input changes state indicating that the car is approaching a
floor.
The first time the initialization procedure is run it is possible that the car is situated
at a level or between levels (as if the car was approaching a level).

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To summaries, the input to the PLC can represent three positions of the car as it
approaches a floor.
- Car approaching floor state (sensor is off)
- Car approaching floor level (sensor is on)
- Car is at level (sensor is off)

If the level 1 sensor is detected the car will travel upwards until the level 2 sensor
is found. At this point the main initialization procedure will be carried out.

This procedure can be also represented as a State Diagram.

As suggested by the flow chart the initialization routine can be divided into a
number of stages:

1. Close the door and release the brake

2. See if car is at level 1
3. Move car to level 2
4. Return car to level 1
5. Turn motor off and apply brake

To disengage the brake, it must be energized. This is an important safety feature: if

there is no power to the elevator, it will be stopped by default.

D. Assignment 4: Basic Elevator Control

Objectives
- To learn about some of the elevator inputs and outputs.
- To learn how it is possible to control the car manually.
- To learn how to write a simple PLC program to move the elevator car.

Practical 1: Move Car to Top then to the Bottom

This practical shows how sequences of actions can be combined together.
Write a program that moves the car to the top and then to the bottom of the
Elevator considering the state diagram below.

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Practical 2: Two Level Elevator with Door Control

Develop a program to extend the functionality of the above to include the following:

Two level (first and top), level push buttons.

Include an initialization routine.
The elevator goes to the bottom floor and waits until the floor 4 pushbutton is
pressed (right hand side of elevator) or floor 1 call pushbutton is pressed to bring
the car back to floor 1. The program is repeated.
To begin to think about this problem consider how it can be decomposed. Thinking
about the problem in terms of state diagrams may be useful. adding the door

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opening and closing routine. Also consider whether your program is to allow
requests whilst the car is moving.
Add bell control. Remember that since the controller may send signals faster than
the electronics of the elevator can accept, it is important to create a delay to
ensure that the bell is rung.
Implement the door open and close routine within a separate subroutine or state.
Consider how the request function may change to cater for the case when the car
is on the level that has been requested.
At this point, the program does not have any interlock. If additional floor buttons
are pressed, the door will open and close while the car is travelling.

Practical 3: Choosing the Correct Floor Sensor

Write a program that provides the following:

Allows the user to select the level sensor that they are interested in looking at by
pressing the car push buttons.
Displays whether the level sensor is high or low by illuminating the 'car moving up'
indicator.
When the program is running the level sensors can be studied by moving the car
with the Manual control switch. This programming can be used as a basis for the
programs explored in the later practicals and assignments.
When running the above program use the Manual switch to set the car at a
particular floor. Press the appropriate Elevator Car floor button to light the 'up'
arrow. Check that the other positions respond in the same way. Note that pressing
any of the other Elevator Car floor buttons, the 'up' arrow is not illuminated.

Practical 4: Stopping at Every Floor - Both Directions

Write a program that provides the following:

Move the car up, stopping at every floor, and moving car down the elevator,
stopping at every floor to form a single program.
Make an enhancement to the program to run the program again after a short delay.
This can be implemented using a timer.

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E. Assignment 5: Visiting Floors using Pushbutton Control

Objectives
- To create a program that implements a simple working elevator that accepts
requests one at a time. Include in the program a door open and close routine
and sound the bell on arrival at the floor.
- To create a simple elevator program where the car can selectively service
floors when An elevator is continually moving.

Practical 1: Visiting All Floors using Request Push buttons

Write a program that does not allow more than one input to be entered into the
system at a time. The car gets to a floor and then waits for the next input. A more
complicated algorithm will be explored in the project 'A Working Elevator' .
When the car is at the required level, turn off the request lights (both in the car and
on the level).

The car and the level push buttons have the same effect. On levels 2 and 3 the
request up and down push buttons operate in the same way. A more complicated
scenario is explored in a later assignment.
Include in your program the car direction arrow to indicate which way the car is
travelling.
Use the ideas explored within the previous practical to determine which direction
the car must travel to service a floor. Think about whether this program would work
in practice, listing how it might be improved.
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F. Assignment 6: A Working Elevator

Objectives

- To understand how to control an elevator using a more complicated algorithm.

- To understand how to determine the highest and lowest levels selected.
- To understand how to make use of directional floor controls.
- To understand how to make use of both floor controls and car pushbutton
controls.

Practical 1: Full Control (Simple Floor Requests)

Algorithm fundamental:

If car is moving up, service those calls up before going back down again. The
reason for adopting such an approach is to save energy.
Consider the algorithm used in Practical 1(Visiting All Floors using Request
Pushbuttons) of Assignment 5. Although this is a working program, the passenger
who pushes the pushbutton fastest gets control of the elevator. This is clearly
undesirable.

The elevator will know about the top and bottom levels, and whether the elevator
needs to travel further to service a demand.
One of the biggest differences between this problem and the 'Visiting All Floors
using Request Push buttons' practical lies with the ability to receive car requests at
any time.
A further complexity lies with how to process the Elevator Car pushbuttons. For
this practical, the Elevator Car push buttons are either ignored or they should have
the same action as the floor pushbuttons. The final practical will complete the
algorithm by adding the car push buttons.
Before beginning to design the program it is useful to think of the problem in terms
of requirements:

- The car must visit the requested floor as quickly as possible.

- The elevator should attempt to minimize the amount of energy used.

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A description of an algorithm that attempts to satisfy these requirements is as

follows:

Move to the first level that has been requested. If there are requests that are higher
than the current level of the car continue moving the car upwards until every
requested floor has been visited. When there are no more requests higher than the
current car level, change the direction of the car and service requests that are
below the current level (ignoring requests that are higher than the current car
level). When there are no further lower requests (or the bottom of the elevator has
been reached), change direction of the car and service requests higher than the
current floor level.
The procedure should be repeated.
Design an algorithm to implement the procedure described This algorithm can be
Divided into a number of steps.

Algorithm:
Perform an initialization routine so the elevator is set to level 1. Set direction to up.
Check for elevator requests

Determine Two status bits:

low remaining and high remaining. This indicates that the elevator has other floors
to service. This bit is determined by calculating the difference between the level
where the car was last recorded, and the highest floor that is to be serviced.
To make it easier, it is recommended that initially the car speed is not changed
when the car departs and leaves floor.

Practical 2: Full Control (Directional Floor Requests)

An example:
Following initialization (where the elevator is initialized to sit at level 1), assume the
following requests: Floor 3 Up, Floor 4 Down, Floor 2 Down. The following
sequence will be executed:

1. All up requests are serviced, Le. in this case only 3U will be serviced.
2. Next the elevator reaches the fourth floor to service 4
3. Finally it services the remaining down requests, which in this case is 2D.

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Use this example as a way to test your routine. Full Control (All Floor Controls)
In full size elevators remember that the passengers do not usually see which floors
the elevator is about to call at (which level push buttons have been pressed by
passengers).
This practical expands the previous practical by adding logic to ensure that the
passengers in the car do not receive more information than they need.

G. Project : Advanced Elevator Programming

Objectives

- To work to extend the knowledge gained in completing the previous

assignments.

Exercise 1: Priority for Top Level

If a request from Level 4 is received, providing that the passengers within the car
have not made any requests, the requests from the other levels are ignored.

Exercise 2: Enhanced Elevator Control

Modify the program so the length of time the doors open and close depend on
whether there is a demand for the elevator either from within the car or from other
levels.

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