Automation of a 3-Phase AC Motor and Assembly Line Using Allen-Bradley MicroLogix 1000

Programmable Logic Controllers (PLCs)

Prepared by:

Steven M. Fuhrman

Faculty Advisors:

Scott Rausch

Interim Department Head/Instructor, Department of Electrical and Computer Engineering

Dr. Alfred Boysen

Professor, Department of Humanities

Program Information:

National Science Foundation

Grant NSF # EEC-1359476

Research Experience for Undergraduates

Summer 2015

South Dakota School of Mines & Technology

501 E. Saint Joseph Street

Rapid City, SD 57701

2

Table of Contents

Abstract ………………………………………………………………………………………… 3

Introduction ……………………………………………………………………………………... 3

Broader Impact …………………………………………………………………………………. 3

Procedure ………………………………………………………………………………………. 3

Materials ……………………………………………………………………………….. 3

Software/Equipment…………………………………………………………………….. 4

Procedures ……………………………………………………………………………… 4

Results ………………………………………………………………………………………….. 5

3-Phase Motor ………………………………………………………………………….. 5

Assembly Line …………...…………………………………………………………….. 5

Discussion ……………………………………………………………………………………… 7

Conclusion …………………………………………………………………………………...… 7

Appendices……………………………………………...……………………………………….. 8

Appendix A: Electrical Schematics …...……………………………………………….. 8

Appendix B: Images …………………………...…………………………………….... 13

Appendix C: Ladder Logic Code ……………………………………………………… 17

References …………………………………………………………………………………..… 20

Acknowledgments …………………………………………………………………………..… 20

3

Abstract

The automation of factory machines is commonly done using programmable logic controllers

(PLCs). Hands-on PLC training stations are helpful to train students how to use and program

PLCs. Two different PLC training setups have been designed, one automating a 3-phase AC

motor-generator set and the other automating a portion of an assembly line. Both of these

machines are automated using Allen-Bradley MicroLogix 1000 PLCs which have been

programmed with ladder logic control programs.

1. Introduction

Programmable logic controllers (PLCs) are widely used in industry for the industrial

automation of factory machines. To give students hands-on experience wiring and programming

PLCs, laboratory setups involving a 3-phase motor and an assembly line machine are designed.

Once these lab setups are built and tested PLC training labs will be developed so these setups can

be integrated into the laboratory curriculum at SDSM&T. For the automation of these machines

Allen-Bradley 1761-L20AWA-5A MicroLogix 1000 Analog PLCs will be used. The 3-phase

motor-generator set is being used as a test instrument that is relatively easy to understand and

work with. This electric machine consists of a 3-phase AC motor that drives a DC generator.

The PLC will be used to turn on and off the relay contactor which provides the AC power for the

motor. This test instrument will serve as a training and experimentation platform for learning

how to wire and program a PLC and to gain understanding about how each of its various types of

inputs and outputs work. The assembly line machine is an IC board component lead cutter that

was used in an assembly line in industry. The implementation of PLC control on this machine

makes for a perfect PLC training station as it demonstrates how a PLC can be used on an actual

machine from industry.

The Allen-Bradley 1761-L20AWA-5A MicroLogix 1000 Analog PLCs have 12 discrete

AC inputs and 8 AC/DC outputs. The inputs will be used to read the position of a switch and the

outputs are used as relays which are programmatically energized and de-energized. They also

have two analog voltage inputs, two analog current inputs and one analog output that can be

configured as an analog voltage or current output. The goal in the control programs and wiring

is to make use of as many of the different types of inputs and outputs as possible. This is to

demonstrate the many capabilities of this PLC and to give students practice using all them.

2. Broader Impact

The broader impact of this project is to have effective laboratory setups for the hands on

teaching of PLCs. Both the 3-phase motor and assembly line machine will be used as PLC

training instruments used in multiple classes at SDSM&T. The assembly line machine rewired

for PLC control provides for an effective training instrument to train students how to properly

wire and program a PLC while at the same time using an actual machine from industry. This

will better prepare students who want to work in the industrial automation field.

3. Procedure

Materials

The main materials used for this project are Allen-Bradley 1761-L20AWA-5A

MicroLogix 1000 PLCs, a 3-phase AC motor-generator set and an assembly line machine. The

4

Allen-Bradley 1761-L20AWA-5A MicroLogix 1000 PLC (shown in image 1) has 12 discrete

AC inputs, two analog voltage inputs and two analog current inputs. It also has 8 relay outputs

and one analog output that can be configured to be an analog current or analog voltage output.

The 3-phase AC motor-generator set (shown in image 2) is a 3-phase motor that is connected to a

DC generator so when the AC motor is powered with 3-phase power the DC generator will

output a steady DC voltage. The Assembly line machine (shown in image 3) is a IC board

component lead cutter that was used in industry on a circuit board production assembly line and

was donated to SDSM&T by Littelfuse.

Image 2: 3-phase motor-generator set Image 3: Assembly line machine

Software/Equipment

The following free software downloads from Rockwell Automation software were made

to program the PLCs: RS Logix Micro English and RS Linx Classic Lite. The RS Logix Micro

English program is the ladder logic programming environment where the ladder logic programs

are written and run. The RS Linx Classic Lite program is used to interface between the PLC and

your PC enabling the RS Logix Micro English program to download a program onto the PLC. It

is important to note that these programs were lite versions which limited the functionality of the

programs, but there was enough functionality for the control programs that were written.

OrCAD Capture CIS Version 9.2 Lite circuit design software was a free software

download that was used to draw up circuit schematics for the PLC control of the 3-phase motor

and assembly line.

Procedures

Automation of 3-Phase AC Motor-generator Set

1. Learn ladder logic programming language

2. Learn about 3-phase power, the 3-phase motor-generator set and the breaker closet

3. Design wiring schematic for implementation of PLC control of motor

4. Wire up 3-phase motor, relay contactor circuit and PLC

5. Write ladder logic control code for the 3-phase motor

6. Turn documentation of 3-phase motor into a lab for future students

Image 1: Allen-Bradley MicroLogix 1000

PLC

5

Automation of Assembly Line Machine

1. Develop an electrical schematic for original wiring of assembly line

2. Identify and determine the ratings of all electrical components on the assembly line

3. Determine what new/additional parts need to be purchased

4. Develop a new electrical schematic for PLC control of assembly line

5. Build mounting fixtures and mount switches, relays, transformer, buzzer, wire terminal

blocks, and PLC on user interface board

6. Wire up electrical components and motors on assembly line

7. Write ladder logic control programs for assembly line

8. Turn documentation for assembly line into 2 different labs for future students

4. Results

3-Phase Motor

For the 3-phase motor an electrical schematic was developed (see Appendix A) that made

use of logic switches that were read into the PLC as analog voltage inputs, one relay output

which drove the relay contactor for the 3-phase power and an analog voltage output which was

measured by a DMM. An effective ladder logic control program was written that uses all of

these inputs and outputs.

The control program Motor On/Off 30s Option (see Appendix C) consists of a main

program and a subroutine program. The main program reads in the two logic switches, the first

logic switch IA/0 acts as a master on/off switch for the motor. The motor will only turn on when

this switch is logic high. The second logic switch IA/1 determines whether or not the 30s Pulse

Subroutine runs or not. The 30s Pulse Subroutine is only active when both logic switches are

logic high. The One-Shot-Rising (OSR) functions were used to ensure that the analog output

voltage is zero volts whenever the 30s Pulse Subroutine is not active and to reset the timers so

that when the 30s Pulse Subroutine is activated there is a full 30s pulse on the first iteration. The

30s Pulse Subroutine consists of two timers that turn the motor on for 30s and off for 30s in an

endless loop while the subroutine is active. It also writes a voltage to the analog output that

increases from 0-10V proportionately as the time of the 30s pulses increase from 0-30s. This

analog output acts as a progress bar indicator.

Assembly Line

An electrical schematic for the original wiring of the assembly line machine was created

to better understand the operation of the assembly line (see Appendix A). This schematic is

complete with color code and wire connectors. Once the all of the electrical components of the

assembly line were taken apart, mounts were made for all of the switches, relays and other

electrical hardware using scrape copper circuit board material and epoxy. This was done so that

they could all be placed on a user interface in such a way that students can clearly see all of the

electrical hardware and wiring. Images of all of the mounts that were made and the completed

user interface can be found in Appendix B. A new electrical schematic has been created that

implements the PLC (see Appendix A). The assembly line control interface (see Appendix B)

consists of two circuit breakers, all of the original control switches, 1 120VAC to 28VAC

transformer, a 12VDC voltage regulator circuit, 2 24VAC coil relays, 2 12VDC coil relays, a

buzzer, 5 fuses, a PLC and two wire connectors, one for the emergency stop switches on the

6

assembly line and one for the motors. The first breaker is the master on/off switch for the PLC

and is rated for a max of 5A. The second breaker is the master on/off for the power to

everything else on the user interface and is rated for a max of 30A. There is also a fuse before

each breaker as an additional safety precaution. Before breaker 1 there is a 1A fuse for the

power to the PLC. Before the second breaker

there is a 20A fuse. The start/stop push

buttons, emergency stop push buttons and the

two 3-position switches are powered with

120VAC and are read as discrete inputs into

the PLC. All of the motors are driven using

external relays. This is because they all

pulled to much current for the relay contacts

of this particular PLC to handle. Two

different types of relays were used, two

24VAC coil relays and two 12VDC relay

coils. This was done because the two

24VAC relay coils were originally on the

assembly line and the only relays we were

able to purchase had DC relay coils. This

also demonstrates how the PLC can be wired

up to drive relays or other motors that are

powered with various AC and DC power

sources. In order to power the two different

types of relay coils the 120VAC to 28VAC

transformer was used to step down the

120VAC to 28VAC for the 24VAC relay

coils and so that the AC voltage to the

12VDC voltage regulator circuit is under the

30VAC maximum voltage. The 12VDC

voltage regulator circuit (Shown in image 4

and 5) consists of a half wave rectifier with

100uF and 47uF capacitors making a DC

input. Then a uA7812C 12VDC voltage

regulator chip is used to step down the

voltage to 12VDC. The output has 47uF and

1uF capacitors to keep a steady 12VDC output. The stable 12VDC power source then is used to

drive the 12VDC relay coils. To connect the user interface to the assembly line two cables were

made with wire connectors. This allows the user interface to be disconnected from the assembly

line for ease of transport and so that programs can be tested with the PLC and relays without

turning on and off all of the motors on the assembly line. There is a fuse on each motor, since

they pull the most current, as added protection if there is a short in the circuit. The buzzer is

wired up to the analog output which varies the intensity of a high pitch beep with the DC voltage

sent to it.

A ladder logic control program was written for the assembly line so that it would function

in a similar way to how the assembly line was originally wired, except the buzzer was used as a

GRNBLU

GRN

D1

1N4007

RED

U2

uA7812C

1 3

2

IN OUT

GN

D

C1100u

12VDC OUT

C247u

D2

1N4007

RED

C41u

BLU

C347u

Image 4: Perfboard of 12VDC voltage regulator circuit.

Image 5: Circuit schematic of 12VDC voltage regulator

circuit.

7

warning alarm to indicate that the lid is open instead of being used as an electronic zero buzzer

for the cutters. The control program, Assembly Line Control 1 (Appendix C), reads in all of the

switch positions. The start push button is read in as a software latching relay, this will only

allow motors to turn on after the start button is pressed. The stop button, two emergency stop

panel switches and lid switch all unlatch the software latching relay turning off the motors.

Since the stop buttons are placed on a lower rung then the start button they override the position

of the start button. The spindle motor and post brush motor are set to turn on when the switch 8

is in the run position (up position). When switch 8 is in the setup position (down position) just

the spindle motor is on. The conveyer motor is on whenever switch 9, the forward/reverse

switch, is not in the neutral position. Going forward only when the switch is in the up position

and going in reverse only when the switch is in the downward position. The buzzer is set to

sound whenever the lid is open and the system is running, meaning the software latching relay is

still latched.

5. Discussion

Successful automated control of the 3-phase motor-generator set with the PLC consists of

a program that can turn the motor on and off with a logic switch and a second logic switch which

activates a subroutine to pulse the motor on/off in 30s increments. This mini demo makes use of

the analog voltage inputs, the relay outputs and the analog output. Successful automated control

of the assembly line has also been accomplished with a PLC control program that simulates how

it could actually be used on an assembly line in industry. The assembly line machine makes use

of the discrete AC inputs, the relay outputs and the analog output. This means between the two

machines all of the different types of inputs and outputs of the PLC will be used except for the

analog current inputs and output.

6. Conclusion

The construction and testing of the 3-phase motor-generator set and assembly line is

complete and ready for implementation in the fall. The PLC wiring schematics were chosen to

give students experience programming with each type of I/O on this PLC. The wiring schematic

for the assembly line includes multiple types of power sources to give students experience

working with the various types while wiring and programming the PLC. In the future control

labs will be written for both machines to train students how to program in ladder logic and to

give them hands on experience with wiring and programming PLCs. For the assembly line, the

implementation of the speed controller through the analog inputs and outputs will be designed.

8

Appendix A

This section is reserved for electrical schematics for the 3-phase motor and assembly line.

Electrical schematic for PLC control of 3-phase motor-generator set

BLUE

GRN

RED

TO 3 PHASE

MOTOR

HOT NEUTRAL

BLACK

85

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RED

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9

Electrical schematic for original wiring of assembly line machine

7P

A

1 2

VIO

GRN

BLK

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D1

RUN

S4

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5 VAC

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10

First design of the electrical schematic for PLC automation of the assembly line

F5 5A

S3

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CR1

T2L2

T3L3

L1T1

SPINDLE BRAKE

CR2

SPINDLEMOTOR

S1

CONVEYORMOTOR

11

Final electrical schematic for the PLC control of the assembly line

BLK

YEL

CR1

L2T2

L3T3

T1L1

SETUP

M2

WHT

GRN

RED

S3

SPINDLE BRAKE

WHT

MICROLOGIX 1000

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C347u

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S5

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+ -BZ1

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GRN

Speed Controller

L1 A+

A-L2

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GRN

S4

BLK

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BLU

RED

NEUTRAL

BLK

F5 5A

BLK

CR2

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T11&2 5

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28

VAC

S2

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F1 20A

BLK

YEL

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U2

uA7812C

1 3

2

IN OUT

GN

DInput End

Emer. Stop

CR3

GRN

M3

YEL

GRN

B1

POST

BRUSH

MOTOR

D2

1N4007

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WHT

WHT

CR4

BLK

YEL

P

PLUG AC MALE

1 2

3

BLK

REVERSE

S11 2

YEL

HOT

WHT

S7

STOP

CONVEYORMOTOR

YEL

RED

D1

1N4007

GRN

GRN

M1

GRN

RED

12

Final electrical schematic for the PLC control of the assembly line with wire connectors

GRN

BLK

P2A

1 2 3 4 5 6

U2

uA

7812C

13

2

INO

UT

GND

YEL

GRN

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CR

4

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85-264VAC

U1

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NOT USEDNOT USED

AC COMI/0I/1I/2I/3

AC COMI/4I/5I/6I/7I/8I/9

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O/1

IA/1 V(+)

IA SHDIA/0 V(+) O/7

NOT USEDOA SHD

OA (-)

IA (-)IA SHD

O/2O/3VAC VDCO/4O/5

IA/2 I(+)IA/3 I(+)

IA I(-)

OA/0 I(+)OA/0 V(+)

O/6

VAC VDC

VAC VDC

WHT

BLK

BLU

RED

RED

BLU

F1

20A

WHT

M3

F3

20A

WHT

YEL

12VDC OUT

BLU

P1B

1234

65

WHT

F5

5A

WHT

RED

D2

1N

40

07

Input End

Emer. Stop

WHT

P4B

1 2

S6

STA

RT

BLK

GRN

GRN

S9

S8

Lid SW

BLK

+-

BZ

1

P2B

1 2 3 4 65RED

P3A

1 2 3 4 5 6

28

VAC

BLK

CR

3

BLK

NEUTRAL

C3

47u

SP

IND

LE

MO

TO

R

T1

1&

25

3&

48

GRN

SP

IND

LE

BR

AK

E

S5

S1

12

BLU

BLK

S2

RED

BLK

M2

PO

ST

BR

US

H

MO

TO

R

GRN

GRN

C4

1u

WHT

WHT

F2

1A

RED

RED

RED

P3B

1 2 3 4 65

YEL

YEL

BLK

YEL

FORWARD

F4

10A

S4

YEL

BLU

GRN

GRN

REVERSE

D1

1N

40

07

CR

2

BLU

BLK

CR

1

L2

T2

L3

T3

T1

L1

M1

BLU

RED

C2

47u

BLK

BLK

RUN

BLK

BLK

P

PL

UG

AC

MA

LE

12

3

WHT

GRN

Sp

ee

d C

on

tro

ller

L1

A+ A-

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GRN

RED

SETUP

P1A

123456

MIC

RO

LO

GIX

10

00

WHT

C1

100u

YEL

BLK

HOT

Output End

Emer. Stop

BLU

B1

BLK

RED

P4A

1 2

S7

STO

P

WHT

BLK

S3

CO

NV

EY

OR

MO

TO

R

GRN

GRN

BLK

GRN

13

Appendix B

This section is reserved for images of constructed electrical component mounts, user interfaces

and laboratory setups.

Image of setup for PLC control of 3-phase motor.

Electrical Component Mounts for Assembly Line

Breaker 1:

14

Breaker 2:

Start/Stop Buttons:

Run/Setup Button:

15

Forward/Reverse Button:

Speed Controller:

Buzzer:

16

Assembly Line Control Interface

17

Assembly Line Machine

Appendix C

This section is reserved for images of ladder logic code and code descriptions.

Motor On/Off 30s Option Program

Main program: Reads logic switches to turn on/off motor or to execute the 30s Pulse Sub-

Routine.

18

30s Pulse Sub-Routine: Sends 30s on/off pulses to 3-phase motor and increases the analog output

from 0-10V as time of the pulse increases from 0-30s.

19

Assembly Line Code: written to simulate how the assembly line could be controlled with the

PLC if it were used in an actual assembly line.

20

References

1. Allen-Bradley. (1998). User Manual: MicroLogix 1000 Programmable Controllers.

Retrieved from http://etidweb.tamu.edu/hsieh/ENTC410/Manual/MicroLogix1000-1761-

um003_-en-p.pdf

2. Petruzella, F. D. (2011). Programmable Logic Controllers (4th ed.). New York, NY:

McGraw-Hill.

3. Ron Beaufort Training. (2009, March 24). 1 - Problem: Mistakes & Misconceptions (AB PLC

Training) [Video file]. Retrieved from https://www.youtube.com/watch?v=T3tnXu-Eywc

4. Ron Beaufort Training. (2009, March 24). 2 - Basic Inputs and Outputs (AB PLC Training)

[Video file]. Retrieved from https://www.youtube.com/watch?v=jhLIOM1gfgk

5. Ron Beaufort Training. (2009, March 24). 3 - Introducing the PLC Processor (AB PLC Training)

[Video file]. Retrieved from https://www.youtube.com/watch?v=xywXrN6AJGs

6. Ron Beaufort Training. (2009, March 24). 4 - Fundamentals of the Scan Sequence (AB PLC

Training) [Video file]. Retrieved from https://www.youtube.com/watch?v=8qqv2M_3DeI

7. Ron Beaufort Training. (2009, March 24). 5 - Understanding Bits and Instructions (AB PLC

Training) [Video file]. Retrieved from https://www.youtube.com/watch?v=iO9UzFafUpE

8. Ron Beaufort Training. (2009, March 24). 6 - Basic Instruction XIC (AB PLC Training) [Video

file]. Retrieved from https://www.youtube.com/watch?v=HniwADNPX5A

9. Ron Beaufort Training. (2009, March 24). 7 - Basic Instruction OTE (AB PLC Training) [Video

file]. Retrieved from https://www.youtube.com/watch?v=q4JSrEVOgok

10. Ron Beaufort Training. (2009, March 24). 8 - Basic Instruction XIO (AB PLC Training) [Video

file]. Retrieved from https://www.youtube.com/watch?v=7Sf6qNRuluc

11. Ron Beaufort Training. (2009, March 24). 9 - Solution: Step-by-Step Analysis (AB PLC Training)

[Video file]. Retrieved from https://www.youtube.com/watch?v=B9HYUbyTKhU

12. Ron Beaufort Training. (2009, March 24). 10 - Which Rung Wins? (AB PLC Training) [Video

file]. Retrieved from https://www.youtube.com/watch?v=rnsQpgrByNI

13. Ron Beaufort Training. (2009, March 24). 11 - Retentive Instructions OTL and OTU (AB PLC

Training) [Video file]. Retrieved from https://www.youtube.com/watch?v=KraWAA_i9GM

14. Q Corporation. (2003). Operators Manual: IVB.

Acknowledgments

Thanks to the National Science Foundation for funding this project through the REU Site:

Bringing Us Together, Improving Communications and Lives grant # EEC-1359476. Special

thanks to Littelfuse for donating the assembly line machine that was used for this project. I

would also like to thank my advisor Scott Rausch for all of the guidance he provided during this

project and Dr. Alfred Boysen for his critics of my speaking and writing.