Programmable Logic ControllersITEC 427

R&D Project Spring 2018

Andrew Spisak, Julian Gonzalez

Allen Bradley Micrologix 1000

1

Table of Contents System Overview 3Diagram of System Configuration 4Internal Coil Address Assignments 4I/O Address Assignment 5

Inputs 5Outputs 5

Register of Date Table Assignments 6Program Print Out 7Controller Program Backup 8Wiring Diagram 8

Connector wiring labeling 9Pin layout of connector 9Stack light wiring 10

Additional Research Documents 10Project Assignment 11

2

System Overview Our goal was to create a control system using an Allen Bradley MicroLogix 1000

PLC to fully operate the servo on and servo off functions of a Mitsubishi Melfa RH-6FH-D industrial robot. Implementing normally open and normally closed start and stop switches, we could control the industrial robot without using the on and off button functions on the Mitsubishi CR750-D. This system uses stack lights to provide an indication of when the industrial robot is on and when it is turned off. When the robot is at work, the stack lights will begin to turn on, and will not turn off until the robot has been manually turned off by the stop switch. The system hopes to accomplish the use of a control system to turn on/off the industrial robot using switches while providing safety with stack lights above the robot to indicate that the robot is doing work.

One of the major features of this project is the Allen Bradley Micrologix 1000 PLC, with this PLC we are able to connect the inputs and outputs of the connection between the industrial robot and the start and stop switches. These switches are another key component to this project, which they serve as the new primary on and off buttons to control when the robot is turned on or off. Another component to this system is the use of RSLogix software on the computer to provide ladder logic for this operation to work. The program we used in RSLogix displays a complete flow of the operation broken down into each rung of code. Using the start and stop switches on the software allowed us to communicate with the PLC and the inputs/outputs of switches used to operate the system. To communicate from the switches on the control board to the industrial robot, we manipulated the RH-6FH-D external cord by pulling back the outer layer of the external wire to use specific colored wires that would indicate a certain function of the industrial robot. Using specific color coded wires to connect to the external port of the Mitsubishi CR750-D, we were able to power on the robot and control certain key power functions that would allow us to use that as a connection to the switches. This was also how we controlled the on/off function of the lights. Using the industrial robot manual that provided what exact color coded wires we needed to use as a connection to the robot.

This system could be used in a conveyor operating environment. Simply using the start and stop switches to control when the robot starts/stops working and lights to provide an indication of when the robot is at work, workers in the company have complete control of the system by one click of a button.

3

Diagram of System Configuration

Internal Coil Address Assignments Address Bit Type Device Function

B: 3/0 Latch Internal bit Latching the servos with robot on/off function

S:4/6 24 VDC Time Switch Time Base

I/O Address Assignment

Inputs

Address I/O Type Device Function

4

I: 0/0 24 VDC Normally Closed PB Stop Servo

I: 0/1 24 VDC Normally Open PB Start Servo

I: 0/2 24 VDC Normally Closed PB Stop Robot

I: 0/3 24 VDC Normally Open PB Start Robot

I: 0/4 24 VDC Normally Closed PB Stop Operation Rights

I: 0/5 24 VDC Normally Open PB Start Operation Rights

Outputs

Address I/O Type Device Function

O: 0/0 24 VDC Robot controller Start Servo

O: 0/1 24 VDC Robot controller Start Robot

O: 0/2 24 VDC Robot controller Stop Servo

O: 0/3 24 VAC Stack light Light flashes when robot is on

O: 0/4 24 VDC Robot controller Stop Operation Rights

O: 0/5 24 VDC Robot controller Stop Robot

Register of Date Table Assignments

5

Program Print Out

6

Controller Program Backup See E-mailed file

- R&D ITEC 427 PLC

Wiring Diagram

7

Connector wiring labeling● (20C) Robot Stop - Pink/Red D (4 dots) ● (17C) Robot Start - Gray/Red D (4 dots) ● (19C) Servo Stop - Yellow/Red D (4 dots) ● (16C) Servo Start - Orange/Red D (4 dots) ● (2C) Common C5 to C20 - Gra/Red A (1 dots) ● (15C) Operation Rights - Pink/Red C (3 dots)

Pin layout of connector

8

Internal and external wiring diagram

Stack light wiring

First unit- Red wire Second unit- White wire Third unit - Black wire Fourth unit - Orange wireFifth unit - Blue wireCommon - Green wire

Additional Research Documents See PDF in E-Mail

- Standard Specification manual page 90 to 96- Stack light manual

9

Project Assignment

System Overview - Julian Gonzalez

Diagram of System Configuration - Julian Gonzalez

I/O Address Assignment - Julian Gonzalez

Internal Coil Address Assignments - Julian Gonzalez

Register of Date Table Assignments - Andrew Spisak

Program Print Out - Andrew Spisak

Controller Program Backup - Andrew Spisak

Wiring Diagram - Andrew Spisak

Additional Research Documents - Andrew Spisak

Formated Paper - Andrew Spisak

10