Student Design Projects in A Programmable Logic Controller PLC Course
Student Design Projects in A Programmable Logic Controller PLC Course
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A Programmable Logic Controller (PLC) is a specialized computer used for the control
and operation of manufacturing process and machinery. A junior/senior level PLC course
in a four-year electrical engineering technology institution mainly covers the following
topics: PLC hardware components, developing fundamental PLC wiring diagrams, basics
of PLC programming, timers, counters, program control instructions, data manipulation
instructions, math instructions, sequencer and shift register instructions, PLC installation,
editing and troubleshooting. After the lectures, students practice PLC programming using
RSLogix® from Rockwell Automation. Students are able to observe the operation of the
program and make necessary modifications as necessary. Towards the end of the
semester, students have learned the basic PLC programming instructions. It is a good
time to enhance their practical problem solving abilities by working on an extensive
design project using PLCs. This paper discusses three separate design projects aided with
PLCs to solve practical process and machinery problems in industrial environments.
Introduction
A programmable Logic Controller (PLC) is a specialized computer used for the control
and operation of manufacturing process and machinery1. It uses a programmable memory
to store instructions and execute functions including on/off control, timing, counting,
sequencing, arithmetic, and data handling 2.
Programmable Logic Controllers (PLC) are used in almost every aspect of industry to
expand and enhance production. Where older automated systems would use hundreds or
thousands of electromechanical relays, a single PLC can be programmed as an efficient
replacement3-5. The functionality of the PLC has evolved over the years to include
capabilities beyond typical relay control. Sophisticated motion control, process control,
distributive control systems, and complex networking have now been added to the PLC’s
functions. Therefore, PLCs provide many advantages over conventional relay type of
control, including increased reliability, more flexibility, lower cost, and communication
capability, faster response time and easier to troubleshoot 6.
• Identify and explain the purpose of the parts of a programmable logic controller
• Use basic PLC relay instructions to write, debug and troubleshoot ladder logic
programs
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• Develop and demonstrate programs showing how the timer and counter functions
are integrated to a PLC
• Properly use program control instructions
• Properly use math and data manipulation instructions
• Describe and use immediate input and output instructions
• Interface digital and analog devices to PLCs
• Explain the need and process for troubleshooting PLC controlled systems
• Prepare students for challenging industrial jobs in the engineering technology
areas
The course spends about 70% time in lecture, and about 30% time in laboratory. Students
are also allowed to use the PLC equipments in their convenience at other times. After the
lecture, students practice PLC programming using RSLogix® from Rockwell
Automation Inc. The PLC programs are then loaded to a Model 1238 PLC trainer from
Future Tek, Inc. Students are able to observe the operation of the program and make
necessary modifications as outlined in the course7.
Students were expected to complete an extensive PLC design project based on the topics
covered in the PLC course11-12. The project involves a proposed problem and solution
with programming of ladder logic program. The final project technical report format and
professional class presentation include the following contents:
The design project started with a project proposal. The project proposal explains the
objective of the project, background information, methodology to be followed and
expected results. The proposals are submitted to the instructor for evaluation. The
proposals are evaluated based on the contents and feasibility of the projects and necessary
modifications are made. Students may choose either a team project of maximum three
students or an individual based project. For a group design project, more contents and
challenges are required by the instructor.
The design project is completed within a period of two weeks. A final project report is
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The PLC program simulates a process tank being filled with a fluid. The tank will start
filling (via a valve) whenever the start process button is enabled and the tank is below
50% full. It will shut off when the tank is 100% full. In case the level sensor is out of
calibration or not working properly, there is a high-level safety limit to prevent the tank
from overfilling. If the high limit is met at a preset value of 102% full the process will
shut down and a strobe light will turn on. Indicator lights are activated when the tank
level reaches 50%, 75% and 100% full as shown in the diagram of the tank in Figure 1.
There is a slight dead band to prevent flickering lights when tank levels vary slightly due
to filling or splashing.
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• On timers (TON)
• Up Counter (CTU)
• One-shot rising instruction (OSR)
• Less than (LES), Less than or Equal to (LEQ), Greater than (GRT), Greater
than or Equal to (GEQ) comparison instructions
• Divide By instruction (DIV) (for scaling analog inputs)
• Input and Output instructions (both internal and external)
A tank information board and its corresponding I/O assignment as presented by the
design team are shown in Figure 2.
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Figure 3: Functional block diagram of power and control circuit of the hybrid boat
project
The I/O assignment is shown as follows. The block diagram of the system as presented
by the design team is shown in Figure 4.
Inputs Outputs
0 Charge / Run Sw 0 Key Motor Controller
1 Throttle Limit Sw 1 Key Generator
2 VBatt 2 Start Generator
4 Generator O/R (ON) 3 Relay Generator
5 Generator O/R (OFF) 4 Relay PV
6 VGen 5 NC
3, 7 & 8 N/C
9 VPV
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Since the MicroLogix ®1000 based PLC uses digital inputs, new signal conditioning
circuits that were already designed and built separately convert the voltage values below
10V DC for the input values to the PLC. In addition, comparator circuits for the voltage
and current thresholds in the charging system trigger the PLC to take action.
moves along a guide track in the floor and can be driven in and out of the trailer.
The conveyor is operated with one pushbutton for forward and the other for reverse
movement. The pushbuttons must be held down the entire time when the conveyor is
moving. Inputs of the system include diffuse type photoelectric sensors on the front and
back of the conveyor to prevent a collision, and inductive proximity switches at the
bottom of the front and back to prevent over travel condition.
Other examples of design projects include process control of production, package and
sort for shipment of candy bars, car wash control, creating a mitered joint for a door
frame prior to assembly, automatic garage door opener and control of traffic light for
eight lanes of traffic.
The Programmable Logic Controllers (PLC) course is a 3 credit hours course for
junior/senior level Electrical Engineering Technology students. Fundamentals of PLC
hardware components, programming and troubleshooting were covered in lectures first.
Then students were expected to complete a PLC design project based on the topics
covered in the course. The design project provides students an opportunity to apply
knowledge acquired in the lecture to real engineering problems. Cases of student PLC
design projects are discussed in this paper. Examples include control of filling a tank,
hybrid boat control and control of a movable conveyor for a trailer. Students developed
creativity, teamwork and practical problem solving skills. Communication skills of the
students were enhanced from writing the final reports and giving the oral presentation in
the class.
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Figure 5. Flowchart of moveable conveyor control systems
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Acknowledgements
The authors would like to thank former undergraduate senior students and current
engineering technologists, Michael Boomer and Benjamin Wagner for designing and
building a hybrid boat and its corresponding PLC control system as part of their senior
design project requirement.
References
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